Defender NAS Workshop Manual (Latest)

Workshop Manual
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Workshop manual
DEFENDER 90 -
NAS
This manual covers vehicles from
1997 model year
01 INTRODUCTION
04 GENERAL SPECIFICATION DATA
05 ENGINE TUNING DATA
07 GENERAL FITTING REMINDERS
09 LUBRICANTS, FLUIDS AND CAPACITIES
10 MAINTENANCE
12 ENGINE 4.0 V8
17 EMISSION CONTROL
19 FUEL SYSTEM SFI
26 COOLING SYSTEM
30 MANIFOLD AND EXHAUST SYSTEM
41 TRANSFER GEARBOX
44 AUTOMATIC GEARBOX
47 PROPELLER SHAFTS
51 REAR AXLE AND FINAL DRIVE
54 FRONT AXLE AND FINAL DRIVE
57 STEERING
60 FRONT SUSPENSION
64 REAR SUSPENSION
70 BRAKES
74 WHEELS AND TYRES
76 CHASSIS AND BODY
80 HEATING AND VENTILATION
82 AIR CONDITIONING
84 WIPERS AND WASHERS
86 ELECTRICAL
88 INSTRUMENTS
Publication Part No. LRL 0088 NAS (2nd Edition)
Published by Rover Technical Communication
' 1996 Rover Group Limited
INTRODUCTION
1
INFORMATION
INTRODUCTION
This workshop manual covers vehicles from 1997
model year onwards. Amendments and additional
pages will be issued to ensure that the manual
covers latest models. Amendments and additions
will be identified by the addition of a dated footer
at the bottom of the page.
This Workshop Manual is designed to assist skilled
technicians in the efficient repair and maintenance of
Land Rover vehicles.
Individuals who undertake their own repairs
should have some skill and training, and limit
repairs to components which do not affect the
safety of the vehicle or its passengers. Any
repairs required to safety critical items such as
steering, brakes, suspension or supplementary
restraint system should be carried out by a Land
Rover Dealer. Repairs to such items should
NEVER be attempted by untrained individuals.
WARNINGS, CAUTIONS and NOTES are given
throughout this Manual in the following form:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to
procedures which must be followed to
avoid damage to components.
NOTE: This calls attention to methods
which make a job easier or gives helpful
information.
DIMENSIONS
The dimensions quoted are to design engineering
specification. Alternative unit equivalents have been
converted from the original specification.
REFERENCES
References to the left or right hand side in the manual
are made when viewing the vehicle from the rear.
With the engine and gearbox assembly removed, the
coolant pump end of the engine is referred to as the
front.
To reduce repetition, operations covered in this
Manual do not include reference to testing the vehicle
after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the vehicle
is carried out particularly where safety related items
are concerned.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that Land Rover parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement parts
and accessories: Safety features embodied in the
vehicle may be impaired if other than Land Rover
parts are fitted. In certain territories, legislation
prohibits the fitting of parts not to the vehicle
manufacturers specification. Torque spanner values
given in the Workshop Manual must be strictly
adhered to. Locking devices, where specified, must be
fitted. If the efficiency of a locking device is impaired
during removal it must be replaced with a new one.
Certain fasteners must not be re-used. These
fasteners are specified in the Workshop Manual.
POISONOUS SUBSTANCES
Many liquids and other substances used are
poisonous and therefore must not be consumed. It is
also advisable to keep all substances away from open
wounds. These substances among others include
anti-freeze, brake fluid, fuel, windscreen washer
additives, air conditioning refrigerant, lubricants and
various adhesives.
01
INTRODUCTION
2
INFORMATION
FUEL HANDLING PRECAUTIONS
The following information provides basic precautions
which must be observed if fuel is to be handled safely.
It also outlines the other areas of risk which must not
be ignored.
This information is issued for basic guidance only, and
in any case of doubt, appropriate enquiries should be
made of your local Fire Officer or Fire Department.
Fuel vapour is highly flammable and in confined
spaces is also very explosive and toxic.
When fuel evaporates it produces 150 times its own
volume in vapour, which when diluted with air
becomes a readily ignitable mixture. The vapour is
heavier than air and will always fall to the lowest level.
It can readily be distributed throughout a workshop by
air current, consequently, even a small spillage of fuel
is very dangerous.
Always have a fire extinguisher containing FOAM CO
2
GAS, or POWDER close at hand when handling fuel,
or when dismantling fuel systems and in areas where
fuel containers are stored.
WARNING: lt is imperative that the battery
is not disconnected during fuel system
repairs as arcing at the battery terminal
could ignite fuel vapour in the atmosphere.
Always disconnect the vehicle battery BEFORE
carrying out work on the fuel system.
Whenever fuel is being handled, transferred or
stored, or when fuel systems are being dismantled
all forms of ignition must be extinguished or
removed, any leadlamps used must be flame proof
and kept clear of spillage.
No one should be permitted to repair components
associated with fuel without first having had fuel
system training.
Hot fuel handling precautions
WARNING: Before commencing any
operation requiring fuel to be drained from
the fuel tank, the following procedure must
be adhered to:
1. Allow sufficient time for the fuel to cool, thus
avoiding contact with hot fuels.
2. Vent the system by removing the fuel filler cap in
a well ventilated area. Refit the filler cap until the
commencement of fuel drainage.
Fuel transfer
WARNING: Fuel must not be extracted or
drained from any vehicle while it is
standing over a pit.
The transfer of fuel from the vehicle fuel tank must be
carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer
tank manufacturers instructions and local regulations,
including attention to grounding of tanks.
Fuel tank removal
A FUEL VAPOUR warning label must be attached to
the fuel tank upon removal from the vehicle.
Fuel tank repair
Under no circumstances should a repair to any tank
be attempted.
INTRODUCTION
3
INFORMATION
SYNTHETIC RUBBER
Many 0 ring seals, flexible pipes and other similar
items which appear to be natural rubber are made of
synthetic materials called Fluoroelastomers. Under
normal operating conditions this material is safe, and
does not present a health hazard. However, if the
material is damaged by fire or excessive heat, it can
break down and produce highly corrosive Hydrofluoric
acid which can cause serious burns on contact with
skin. Should the material be in a burnt or overheated
condition handle only with seamless industrial gloves.
Decontaminate and dispose of the gloves immediately
after use.
If skin contact does occur, remove any contaminated
clothing immediately and obtain medical assistance
without delay. In the meantime, wash the affected
area with copious amounts of cold water or limewater
for fifteen to sixty minutes.
RECOMMENDED SEALANTS
A number of branded products are recommended in
this manual for use during maintenance and repair
work.
These items include:
HYLOMAR GASKET AND JOINTING COMPOUND
and
HYLOSIL RTV SILICONE COMPOUND.
They should be available locally from garage
equipment suppliers.
USED ENGINE OIL
WARNING: Prolonged and repeated
contact with engine or motor oil will result
in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
Used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities should be provided.
Handling precautions
1. Avoid prolonged and repeated contact with oils,
particularly used engine oils.
2. Wear protective clothing, including impervious
gloves where applicable.
3. Do not put oily rags in pockets.
4. Avoid contaminating clothes, particularly
underwear, with oil.
5. Overalls must be cleaned regularly. Discard
unwashable clothing and oil impregnated
footwear.
6. First aid treatment must be obtained immediately
for open cuts and wounds.
7. Use barrier creams, before each work period, to
help the removal of oil from the skin.
8. Wash with soap and water to ensure all oil is
removed (skin cleansers and nail brushes will
help). Preparations containing lanolin replace the
natural skin oils which have been removed.
9. Do not use gasoline, kerosene, diesel fuel,
petrol, thinners or solvents for washing the skin.
10. If skin disorders develop, obtain medical advice.
11. Where practicable, degrease components prior
to handling.
12. Where there is a risk of eye contact, eye
protection should be worn, for example, goggles
or face shields; in addition an eye wash facility
should be provided.
Disposing of used oils
Environmental protection precaution
It is illegal to pour used oil onto the ground, down
sewers or drains, or into waterways.
Dispose of used oil through authorised waste disposal
contractors. If in doubt contact your Local Authority for
advice on disposal facilities.
01
INTRODUCTION
4
INFORMATION
ACCESSORIES AND CONVERSIONS
DO NOT FIT unapproved accessories or conversions,
as they could affect the safety of the vehicle.
Land Rover will not accept liability for death, personal
injury, or damage to property which may occur as a
direct result of the fitting of non-approved conversions
to the vehicle.
WHEELS AND TYRES
WARNING: DO NOT replace the road
wheels with any type other than genuine
Land Rover wheels which are designed for
multi-purpose on and off road use and have very
important relationships with the proper operation
of the suspension system and vehicle handling.
Replacement tyres must be of the make and sizes
recommended for the vehicle, and all tyres must
be the same make, ply rating and tread pattern.
STEAM CLEANING
To prevent consequential rusting, any steam cleaning
within the engine bay MUST be followed by careful
re-waxing of the metallic components affected.
Particular attention must be given to the steering
column, engine coolant pipes, hose clips and ignition
coil bracket.
SPECIFICATION
The specification details and instructions set out in
this Manual apply only to a range of vehicles and not
to any one. For the specification of a particular vehicle
purchasers should consult their Dealer
The Manufacturer reserve the right to vary their
specifications with or without notice, and at such times
and in such manner as they think fit. Major as well as
minor changes may be involved in accordance with
the Manufacturers policy of constant product
improvement.
Whilst every effort is made to ensure the accuracy of
the particulars contained in this Manual, neither the
Manufacturer or Dealer, by whom this Manual is
supplied, shall in any circumstances be held liable for
any inaccuracy or the consequences thereof.
SPECIAL SERVICE TOOLS
The use of approved special service tools is
important. They are essential if service operations are
to be carried out efficiently, and safely. Where special
tools are specified, only these tools should be used
to avoid the possibility of personal injury or
damage to the components. Also the amount of time
which they save can be considerable.
Every special tool is designed with the close
co-operation of Land Rover, and no tool is put into
production which has not been tested and approved
by us. New tools are only introduced where an
operation cannot be satisfactorily carried out using
existing tools or standard equipment. The user is
therefore assured that the tool is necessary and that it
will perform accurately, efficiently and safely.
Special tools bulletins will be issued periodically giving
details of new tools as they are introduced.
All orders and enquiries from the United Kingdom
should be sent direct to V. L. Churchill. Overseas
orders should be placed with the local V. L. Churchill
distributor, where one exists. Countries where there is
no distributor may order direct from:
V. L. Churchill Limited,
PO Box 3,
Daventry, Northants,
England, NN11 4NF.
The tools recommended in this Workshop Manual are
listed in a multi-language illustrated catalogue,
obtainable from:
Messers. V. L. Churchill at the above address,
or from:
Land Rover Publications,
Charactor Mailing
Haysham Road,
Bootle,
Merseyside, L70 1JL,
COPYRIGHT
' 1996 Rover Group Limited
All rights reserved. No part of this publication may be
produced, stored in a retrieval system or transmitted
in any form, electronic, mechanical, recording or other
means without prior written permission of Rover
Group.
INTRODUCTION
5
INFORMATION
JACKING
The following instructions must be carried out before
raising the vehicle off the ground.
1. Use a solid level ground surface.
2. Apply parking brake.
3. Select P (Park) in main gearbox.
4. Select Low range in transfer gearbox.
CAUTION: To avoid damage occurring to
the under body components of the vehicle
the following jacking procedures must be
adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS.
Body structure
Bumpers
Fuel lines
Brake lines
Front radius arms
Panhard rod
Steering linkage
Rear Trailing links
Fuel tank
Engine sump
Gearbox bell housing
Jack or support vehicle by axles only.
Vehicle jack
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOT use the jack for any other purpose. Refer to
Owners Manual for vehicle jack location points and
procedure. Never work under a vehicle supported by
the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used, see J6083.
CAUTION: Do not commence work on the
underside of the vehicle until suitable
stands have been positioned under the
axle.
Raise front of the vehicle
1. Position cup of hydraulic arm under differential
casing.
NOTE: The differential casing is not
central to the axle. Care should be taken
when raising the front road wheels off the
ground as the rear axle has less sway stiffness.
2. Raise front road wheels to enable an axle stand
to be installed under left hand axle tube.
3. Position an axle stand under right hand axle
tube, carefully lower jack until axle sits securely
on both axle stands, remove trolley jack.
01
INTRODUCTION
6
INFORMATION
4. Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5. Reverse procedure when removing vehicle from
stands.
Raise rear of vehicle
1. Position cup of hydraulic arm under differential
casing.
2. Raise vehicle to enable axle stands to be
installed under left and right hand axle tubes.
3. Lower jack until axle sits securely on axle
stands, remove trolley jack.
4. Before commencing work on underside of
vehicle re-check security of vehicle on stands.
5. Reverse procedure when removing vehicle from
stands.
HYDRAULIC VEHICLE RAMP (FOUR POST)
Use only a drive on type ramp which supports vehicle
on its own road wheels. If a wheel-free condition is
required, use a drive on ramp incorporating a
wheel-free system providing support beneath axle
casings. Alternatively, place vehicle on a firm, flat floor
and support on axle stands.
TWO POST VEHICLE RAMPS
The manufacturer of LAND ROVER VEHICLES
DOES NOT recommend using Two Post ramps
employing four adjustable support arms. These
are NOT considered safe for Land Rover vehicles.
If a vehicle is raised on a Two Post ramp,
responsibility for safety of the vehicle and
personnel performing service operations lies with
the Service Provider.
DYNAMOMETER TESTING
WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.
Four wheel dynamometers
Provided that front and rear dynamometer rollers are
rotating at identical speeds and that normal workshop
safety standards are applied, there is no speed
restriction during testing except any that may apply to
the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
If brake testing on a single axle rig is necessary it
must be carried out with propeller shaft to rear axle
removed, AND neutral selected in BOTH main
gearbox and transfer gearbox. When checking brakes,
run engine at idle speed to maintain servo vacuum.
If checking engine performance, the transfer box must
be in high range and propeller shaft to stationary axle
must be removed.
INTRODUCTION
7
INFORMATION
TOWING
CAUTION: The vehicle has permanent
four-wheel drive. The following towing
instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes.
1. Turn ignition key to position I to release steering
lock.
2. Select neutral in main gearbox and transfer
gearbox.
3. Secure tow rope, chain or cable to front towing
eyes.
4. Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Greater pedal pressure will be required to apply
the brakes, the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should be used only
in normal road conditions, snatch recovery
should be avoided.
Suspended tow by breakdown vehicle
1. If the front axle is to be trailed, turn ignition key
to position 1 to release steering lock.
2. Select neutral in main gearbox and transfer
gearbox.
CAUTION: The steering wheel and/or
linkage must be secured in a straight
ahead position. DO NOT use the steering
lock mechanism for this purpose.
TRANSPORTING THE VEHICLE BY TRAILER
Lashing/towing eyes are provided on front and rear of
the chassis side members to facilitate the securing of
the vehicle to a trailer or other means of
transportation.
CAUTION: Underbody components must
not be used as lashing points.
Install vehicle on trailer and apply park brake. Select
N (Neutral) in main gearbox.
01
INTRODUCTION
8
INFORMATION
JUMP STARTING
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
flames, sparks or lighted tobacco are brought
near battery. When charging or using a battery in
an enclosed space, always provide ventilation and
shield your eyes.
Keep out of reach of children. Batteries contain
sulphuric acid. Avoid contact with skin, eyes, or
clothing. Also, shield eyes when working near
battery to protect against possible splashing of
acid solution. In case of acid contact with skin,
eyes, or clothing, flush immediately with water for
a minimum of fifteen minutes. If acid is swallowed,
drink large quantities of milk or water, followed by
milk of magnesia, a beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
1. Position vehicles so that jump leads will reach,
ensuring that vehicles DO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on floor adjacent to vehicle.
2. Ensuring that ignition and all electrical
accessories are switched off, that parking brake
is applied and neutral is selected on a manual
gearbox, with an automatic gearbox select
neutral (N) or park (P) and then connect the
jump leads as follows;
A. Connect one end of first jumper cable to positive
(+) terminal of booster battery.
B. Connect other end of first jumper cable to
positive (+) terminal of discharged battery.
C. Connect one end of second jumper cable to
negative terminal of booster battery.
D. Connect other end of second jumper cable to a
good earth point on the engine, NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY. Keep jumper lead away from moving
parts, pulleys, drive belts and fan blade
assembly.
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion.
3. If booster battery is installed in another vehicle,
start engine and allow to idle.
4. Start engine of vehicle with discharged battery,
following starting procedure in Owners Manual.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failing
to follow this instruction could result in
irrepairable damage to catalysts.
5. Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
6. Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.
INTRODUCTION
9
INFORMATION
ABBREVIATIONS AND SYMBOLS USED IN THIS
MANUAL
Across flats (bolt size) AF ............................................
After bottom dead centre ABDC ...................................
After top dead centre ATDC .........................................
Alternating current a.c. .................................................
Ampere A or amp ........................................................
Ampere hour amp hr ....................................................
Before bottom dead centre BBDC ................................
Before top dead centre BTDC ......................................
Bottom dead centre BDC .............................................
Brake horse power bhp ................................................
British Standards BS ....................................................
Carbon monoxide CO ..................................................
Centimetre cm .............................................................
Centigrade (Celsius) C ................................................
Cubic centimetre cm
3
...................................................
Cubic inch in
3
...............................................................
Degree (angle) deg or ...............................................
Degree (temperature) deg or .....................................
Diameter dia. ...............................................................
Direct current d.c. .........................................................
Electronic Control Unit ECU ........................................
Electronic Fuel Injection EFI ........................................
Fahrenheit F .................................................................
Feet ft ...........................................................................
Feet per minute ft/min ..................................................
Fifth 5th ........................................................................
First 1st ........................................................................
Fluid ounce fl oz ..........................................................
Foot pounds (torque) lbf ft ............................................
Fourth 4th .....................................................................
Gramme (force) gf ........................................................
Gramme (mass) g ........................................................
Gallons gal ...................................................................
Gallons (US) US gal .....................................................
High tension (electrical) H.T. ........................................
Internal diameter I.D. ...................................................
Inches of mercury in. Hg ..............................................
Inches in ......................................................................
Kilogramme (force) kgf .................................................
Kilogramme (mass.) kg ................................................
Kilogramme centimetre (torque) kgf.cm .......................
Kilogramme per square millimetre kgf/mm
2
.................
Kilogramme per square centimetre kgf/cm
2
.................
Kilogramme metres (torque) kgf.m ..............................
Kilometres km ..............................................................
Kilometres per hour km/h .............................................
Kilovolts kV ...................................................................
Left-hand LH ................................................................
Left-hand steering LHStg .............................................
Left-hand thread LHThd ...............................................
Litres l or litre ...............................................................
Low tension l.t. .............................................................
Maximum max. ............................................................
Metre m ........................................................................
Millilitre ml ....................................................................
Millimetre mm ...............................................................
Miles per gallon mpg ....................................................
Miles per hour mph ......................................................
Minute (angle) ............................................................
Minus (of tolerance) - ...................................................
Negative (electrical) - ...................................................
Newton metres (torque) Nm ........................................
Number No. .................................................................
Ohms ohm ...................................................................
Ounces (force) ozf .......................................................
Ounces (mass) oz ........................................................
Ounce inch (torque) ozf.in. ..........................................
Outside diameter O.D. .................................................
Part number Part No. ...................................................
Percentage % ...............................................................
Pints pt .........................................................................
Pints (US) US pt ...........................................................
Plus (tolerance) + .........................................................
Positive (electrical) + ....................................................
Pound (force) lbf ..........................................................
Pounds inch (torque) in.lbf. ..........................................
Pound (mass) lb ...........................................................
Pounds per square inch PSI or lbf/in
2
..........................
Ratio : ...........................................................................
Reference ref. ..............................................................
Revolution per minute rev/min .....................................
Right-hand RH .............................................................
Second (angle) " ...........................................................
Second (numerical order) 2nd ......................................
Specific gravity sp.gr. ...................................................
Square centimetres cm
2
...............................................
Square inches in
2
.........................................................
Standard wire gauge s.w.g. .........................................
Synchroniser/Synchromesh synchro. ..........................
Third 3rd .......................................................................
Top dead centre TDC ..................................................
United Kingdom UK ......................................................
Vehicle Identification Number VIN ...............................
Volts V .........................................................................
Watts W .......................................................................
SCREW THREADS
American Standard Taper Pipe NPTF .........................
British Standard Pipe BSP ...........................................
Unified Coarse UNC ....................................................
Unified Fine UNF .........................................................
01
INTRODUCTION
10
INFORMATION
CROSS REFERENCE OF EMISSION SYSTEM
TERMINOLOGY
NEW TERM (ACRONYM)
Accelerator pedal (AP) .................................................
Air cleaner (ACL) ..........................................................
Air conditioning (AC) ....................................................
Battery positive voltage (B+) ........................................
Closed loop (CL) ..........................................................
Closed throttle position (CTP) ......................................
Canister purge valve (CANPV) ....................................
Data link connector (DLC) ...........................................
Diagnostic trouble code (DTC) .....................................
Distributor ignition (DI) .................................................
Engine control module (ECM) ......................................
Engine coolant level (ECL) ...........................................
Engine coolant temperature (ECT) ..............................
Engine coolant temperature sensor (ECTS) ................
Engine speed (RPM) ....................................................
Evaporative emission system (EVAP) ..........................
Engine fuel temperature sensor (EFTS) ......................
4th gear, 3rd gear etc. (4GR, 3GR) ..............................
Fuel pump (FP) ............................................................
Fan control module (FCM) ...........................................
Generator (GEN) ..........................................................
Ground (GND) ..............................................................
Heated oxygen sensor (H02S) ....................................
Idle air control (IAC) ......................................................
Idle air control valve (IACV) .........................................
Ignition control module (ICM) .......................................
Inertia fuel shutoff (IFS) ................................................
Inertia fuel shutoff switch (IFSS) ..................................
Intake air temperature (IAT) .........................................
Malfunction indicator lamp (MIL) ..................................
Manifold vacuum zone (MVZ) ......................................
Mass air flow sensor (MAFS) .......................................
Multiport fuel injection (MFI) ........................................
On board diagnostic (OBD) ..........................................
Open loop (OL) ............................................................
Park/neutral position (PNP) .........................................
Park/neutral position switch (PNPS) ............................
Programmable read only memory (PROM) ..................
Relay module (RM) ......................................................
Service reminder indicator (SRI) ..................................
Solid state relay module (SSRM) .................................
Three way catalytic converter (TWC) ..........................
Throttle body (TB) ........................................................
Throttle position sensor (TPS) ......................................
Torque converter clutch (TCC) ....................................
Transmission range (TR) ..............................................
Transmission range selector (TRS) .............................
Vehicle speed sensor (VSS) ........................................
Wide open throttle (WOT) ............................................
OLD TERM (ACRONYM)
Throttle pedal (-) ..........................................................
Air cleaner (-) ...............................................................
Air conditioning (AC) ....................................................
Battery plus, bat +, bat feed (B+) .................................
Closed loop (-) .............................................................
Closed throttle, idle position (-) ....................................
Charcoal canister purge valve (-) .................................
Serial link (-) ................................................................
Fault code (-) ...............................................................
Electronic ignition (-) ....................................................
Electronic control unit (ECU) ........................................
Coolant level (-) ...........................................................
Coolant temperature (temp) .........................................
Coolant temperature thermistor (-) ..............................
Engine speed (rev/min) ................................................
Evaporative loss system (ELC) ...................................
Fuel temperature thermistor (-) ....................................
Fourth gear, 3rd gear (-) ..............................................
Fuel pump (-) ...............................................................
Condenser fan timer (-) ................................................
Alternator (-) ................................................................
Ground, earth (B-) ........................................................
Lambda (02) sensor (-) ................................................
Idle speed control (ISC) ................................................
Stepper motor (-) .........................................................
Ignition module (-) ........................................................
Inertia switch (-) ...........................................................
Inertia switch (-) ...........................................................
Intake temperature/ambient temperature (-) ................
EFI warning lamp (-) ....................................................
Manifold depression, vacuum (-) .................................
Air flow meter (-) ..........................................................
Electronic fuel injection (EFI) .......................................
Fault code display unit (-) ............................................
Open loop (-) ...............................................................
Park or neutral (-) .........................................................
Start inhibit switch (-) ...................................................
Chip, PROM (PROM) ...................................................
Relay (-) .......................................................................
Check engine light (-) ...................................................
Control unit (-) ..............................................................
Catalyst, catalytic converter (CAT) ..............................
Throttle housing (-) ......................................................
Throttle potentiometer (-) .............................................
Direct drive clutch (DDC) ..............................................
Transmission gear (-) ...................................................
Shift lever, shifter (-) ....................................................
Road speed transducer (-) ...........................................
Full throttle, wide open throttle (WOT) .........................
INTRODUCTION
11
INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
An adhesive label containing the Vehicle Identification
Number, date of manufacture and gross axle weight
ratings is positioned in a recess on the LH side of the
drivers footwell. The information also includes wheel
and tyre sizes and tyre pressures at gross axle weight
ratings.
Key to vehicle identification label
A. Month and year of manufacture
B. Gross vehicle weight rating
C. Gross axle weight rating for front axle
D. Gross axle weight rating for rear axle
E. Vehicle identification number (17 digits)
F. Vehicle identification number - bar code
The VIN is also stamped on a plate visible through the
LH side of the windscreen.
The number is also stamped on the RH side of the
chassis to the rear of the front lashing eye.
01
INTRODUCTION
12
INFORMATION
LOCATION OF IDENTIFICATION NUMBERS
Engine serial number - V8i engine
Stamped on a cast pad on the cylinder block, between
numbers 3 and 5 cylinders.
NOTE: The appropriate engine
compression ratio is stamped above the
serial number.
Automatic gearbox serial number
The serial number is stamped on a plate attached to
the LH side of the casing.
Transfer gearbox serial number
The serial number is stamped on the LH side of the
gearbox casing below the mainshaft rear bearing
housing adjacent to the bottom cover, see J6092
Front axle serial number
Serial number is stamped on the front of LH axle tube.
Rear axle serial number
Serial number is stamped on rear of LH axle tube.
INTRODUCTION
13
INFORMATION
FAULT DIAGNOSTIC EQUIPMENT
TestBook
Land Rover Vehicles are equipped with substantial
electronics to provide the best performance from the
vehicles systems.
Diagnostic equipment named TestBook is available to
expand the diagnostic abilities of the dealer workshop.
This repair manual is produced with TestBook in mind.
Features of TestBook include :-
Fully upgradable support for the technician.
Structured diagnostics to accommodate all skill
levels.
Touch screen operation.
Direct print out of screen information and test
results.
ELECTRICAL REFERENCE LIBRARY
The Electrical Reference Library is a separate
publication intended for use by trained Land Rover
technicians as an aid to diagnosing electrical faults.
READING THIS MANUAL
This manual is divided into sections shown on the
contents page, alongside a range of icons, familiar to
service technicians.
Relevant information is contained within each of these
sections. These are further divided into the following
sub-sections which appear at the foot of each page :-
Description and operation.
Fault diagnosis.
Adjustment.
Repair.
Overhaul.
Specifications, Torque.
To avoid repeating information through the sections,
where part of the repair operation impacts on another
section, a cross reference is given to direct the reader
to where the information is sited.
For example:
The maintenance section states the need to renew
auxiliary drive belt. A cross reference sites this
information in: Section: Electrical
- Sub-section: Repairs
- Heading: Auxiliary drive belt
American terminology.
A few words used in this manual differ to words used
in America. Where this occurs the American word is
placed inside square brackets. For example: bonnet
[hood], wing [fender], ramp [hoist].
GENERAL SPECIFICATION DATA
1
INFORMATION
ENGINE 4.0 V8i
Type V8i .................................................................................
Number of cylinders Eight, two banks of four .........................................................
Bore 94,00 mm ................................................................................. 3.70 in
Stroke 71,12 mm ............................................................................... 2.80 in
Capacity 3950 cm
3
........................................................................... 241 in
3
Compression ratio 9.35:1 ............................................................
Valve operation Overhead by push-rod ................................................................
Maximum power 140kW at 4750 rev/min ...............................................................
Crankshaft
Main journal diameter 63,500-63,487 mm ....................................................... 2.500-2.4995 in
Minimum regrind diameter 62,471-62,484 mm ............................................ 2.459-2.260 in
Maximum out of round 0,040 mm .................................................. 0.0016 in
Crankpin journal diameter 55,513-55,500 mm ................................................ 2.1855-2.1850 in
Minimum regrind diameter 54,484-54,497 mm ............................................... 2.1450-2.1455 in
Crankshaft end thrust - end float
Taken on thrust washers of centre main bearing 0,10-0,20 mm .......... 0.004-0.008 in
Maximum run-out 0,08 mm ............................................................. 0.003 in
Main bearings
Number and material 5, Lead-indium overlay ........................................................
Diametrical clearance 0,015-0,060 mm ....................................................... 0.0006-0.0024 in
Undersize bearing shells 0,254 mm, 0,508 mm .................................................. 0.010 in, 0.020 in
Connecting rods
Type Horizontally split big-end, plain small-end .................................................................................
Length between centres 155,12-155,22 mm ................................................... 6.107-6.111 in
Big-end bearings
Type and material Lead-indium overlay ............................................................
Diametrical clearance 0,015-0,060 mm ....................................................... 0.0006-0.0024 in
End-float crankpin 0,15-0,36mm ............................................................ 0.006-0.014 in
Undersize bearing shells 0,25 mm, 0,50 mm .................................................. 0.010, 0.020 in
Piston/gudgeon pins
Length 60.00-60,50 mm .............................................................................. 2.362-2.382 in
Diameter 23,995-24,000 mm .......................................................................... 0.9447-0.9449 in
Fit-in connecting rod Press fit .........................................................
Clearance in piston 0,006-0,015 mm .......................................................... 0.0002-0.0006 in
04
2
INFORMATION
Pistons
Clearance in bore, measured at bottom
of skirt at right angles to piston pin 0,020-0,050 mm ................................... 0.0008-0.0020 in
Piston rings
Number of compression rings 2 ..........................................
Number of control rings 1 ....................................................
No 1 compression ring Molybdenum barrel faced .....................................................
No 2 compression ring Tapered and marked T or TOP .....................................................
Width of compression rings 1,48-1.49 mm .............................................. 0.058-0.059 in
Top 1,21-1,23 mm .......................................................................... 0.047-0.048 in
Compression ring gap 0,40-0,65 mm ...................................................... 0.016-0.26 in
Top 0.3-0.5 mm .......................................................................... 0.012-0.020 in
Oil control ring type Aclonoform ..........................................................
Oil control ring width 3,0 mm ......................................................... 0.118 in
Oil control ring rail gap 0,38-1,40 mm ..................................................... 0.015-0.055 in
Camshaft
Location Central ...........................................................................
Number of bearings 5 ..........................................................
Bearing type Tin-aluminium - Non serviceable .....................................................................
Camshaft end-float 0. ...........................................................
Drive Chain 9,52 mm pitch x 54 pitches. .................................................................................
Tappets
Type Hydraulic-self-adjusting .................................................................................
Valves
Length: Inlet 116,59-117,35 mm .................................. 4.590-4.620 in
Exhaust 116,59-117,35 mm ........................... 4.590-4.62 in
Seat angle: Inlet 45to 4525 ..................................
Exhaust 45to 4525 ...........................
Head diameter: Inlet 39,75-40,00 mm .................................. 1.565-1.575 in
Exhaust 34,23-34,48 mm ........................... 1.347-1.357 in
Stem diameter: Inlet 8,664-8,679 mm .................................. 0.341-0.342 in
Exhaust 8,651-8,666 mm ........................... 0.340-0.341 in
Stem to guide clearance: Inlet 0,025-0,066 mm .................................. 0.001-.0026 in
Exhaust 0,038-0,078 mm ........................... 0.0015-0.003 in
Valve lift (Inlet and Exhaust) 9,94 mm ............................................ 0.391 in
Valve spring fitted length at pressure of 29,5 kg, 65 lb 40,4 mm .... 1.590 in
Lubrication
System type Wet sump, pressure fed .....................................................................
Oil pump type Eccentric rotor ...................................................................
Oil pressure at 2400 rev/min with engine
at running temperature 2.1 - 2.8 bar ..................................................... 30 - 40 lb/in
2
Oil filter - internal Wire screen, pump intake filter. ..............................................................
Oil filter - external Full flow, self-contained cartridge .............................................................
3
INFORMATION
ENGINE MANAGEMENT SYSTEM (GEMS)
Fuel system type Sagam-Lucas Gems hot wire system electronically ..............................................................
controlled
Fuel pump-make/type High pressure electrical, immersed in the fuel tank ......................................................
Fuel pump delivery pressure 2.4-2.6 bar ............................................ 34-37 lbf/in
2
Fuel filter In-line filter canister type ..........................................................................
Mass air flow sensor (MAF)
Make and type Lucas Hot Wire 20AM .................................................................
Injectors
Make and type Lucas D1000 .................................................................
Engine Control Module (ECM)
Make and type Lucas GEMS 8.2 .................................................................
Fuel pressure regulator
Make and type Lucas 8RV .................................................................
Fuel temperature sensor
Make and type Lucas 6TT .................................................................
Coolant temperature sensor
Bypass air valve (Stepper motor)
Make and type Lucas 3ACM .................................................................
Throttle position sensor
Make and type Lucas 3TP .................................................................
Heated oxygen sensor
Make and type Lucas 4LS - heated .................................................................
Camshaft position sensor
Make and Land Rover part no. Honeywell ERR2261 .........................................
Crankshaft position sensor
Make and type Lucas 4CS .................................................................
Knock sensor
Make and type Lucas 2KS .................................................................
04
4
INFORMATION
Intake air temperature sensor
Ignition coils
Make and type Lucas 2DIS2 .................................................................
COOLING SYSTEM
Type Pressurized system with cross-flow radiator and .................................................................................
remote header tank, thermostat control, pump and fan
assisted. Water and antifreeze mixture as coolant.
Type of pump Centrifugal impellor, belt driven ...................................................................
Thermostat 88
0
C ....................................................................... 190
0
F
Expansion tank cap pressure - system pressure 1.0 bar ............. 15 lbf/in
2
Fan and viscous coupling assembly 11 blade axial flow 433mm, 17 in diameter. ................................
5
INFORMATION
AUTOMATIC TRANSMISSION
Automatic gearbox
Model ZF4HP22 ...............................................................................
Type Four speed and reverse epicylic gears with fluid .................................................................................
torque converter and lock-up
Transfer gearbox
LT230Q Two speed reduction on main gearbox output, front ............................................................................
and rear drive permanently engaged.
Transfer gearbox ratios:
High 1.211:1 .........................................................................
Low 3.269:1 .........................................................................
Automatic gearbox ratios
4th 0.728:1 ...........................................................................
3rd 1.000:1 ...........................................................................
2nd 1.480:1 ..........................................................................
1st 2.480:1 ...........................................................................
Reverse 2.086:1 ...................................................................
Overall ratios - final drive High transfer .............................................. Low transfer
4th 3.46:1 ........................................................................... 9.34:1
3rd 4.75:1 ........................................................................... 12.83:1
2nd 7.03:1 .......................................................................... 18.98:1
1st 11.78:1 ........................................................................... 31.80:1
Reverse 9.91:1 ................................................................... 26.75:1
Propeller shafts
Type
Front Solid bar 28.6mm, 1.125 in diameter .................................................................................
Rear Tubular 51mm, 2.00 in diameter .................................................................................
Universal joints Open type Hookes O3EHD .................................................................
Rear axle
Type Spiral bevel, fully floating shafts .................................................................................
Ratio 3.54:1 .................................................................................
Front axle
Type Spiral bevel, enclosed constant velocity joints, fully .................................................................................
floating shafts
Angularity of universal joint on full lock 32 ............................
Ratio 3.54:1 .................................................................................
04
6
INFORMATION
SHIFT SPEEDS - AUTOMATIC ZF
OPERATION SELECTOR VEHICLE SPEED ENGINE SPEED
POSITION APPROX APPROX RPM
KICKDOWN (KD)
MPH KPH
KD4 - 3 D 92 - 100 149 - 164
KD3 - 2 3(D) 57 - 62 99 - 108
KD2 - 1 2(D,3) 30 - 37 48 - 61
KD3 - 4 D N/A N/A
KD2 - 3 D(3) 66 - 69 105 - 114 4750 - 5200
KD1 - 2 D(3,2) 37 - 44 61 - 70 4600 - 5250
FULL THROTTLE (FT)
FT4 - 3 D 67 - 73 107 -118
FT3 - 2 3(D) 44 - 53 70 - 80
FT3 - 4 D 81 - 88 130 - 141 3980 - 4330
FT2 - 3 D(3) 60 - 66 96 - 105 4350 - 4800
FT1 - 2 D(3,2) 32 - 37 52 - 61 3950 - 4650
PART THROTTLE (PT)
PT4 - 3 D 51 - 60 82 - 94
PT3 - 2 D(3) 32 - 41 53 - 65
PT2 - 1 D(3,2) 11 - 13 18 - 21
LIGHT THROTTLE (LT)
LT3 - 4 D 28 - 33 47 - 54 1430 - 1650
LT2 - 3 D(3) 20 - 24 32 - 38 1420 - 1820
LT1 - 2 D(3,2) 10 -11 15 - 18 1180 - 1220
ZERO THROTTLE (ZT)
ZT4 - 3 D 21 - 27 34 - 45
ZT3 - 2 D(3) 13 - 16 21 - 26
ZT2 - 1 D(3,2) 7 - 8 11 - 12
TORQUE CONVERTER
Lock up (IN) D 56 - 59 89 - 94 1875 - 2000
Unlock (OUT) D 54 -57 85 - 91 1825 - 1930
NOTE: The speeds given in the above chart are approximate and only intended as a guide. Maximum shift
changes should take place within these tolerance parameters.
7
INFORMATION
STEERING
Power steering box
Make and type Adwest Varamatic - worm and roller box .................................................................
Ratio Variable: straight ahead 19.3:1 to 17.2:1 on lock .................................................................................
Steering wheel turns lock to lock 3.75 ......................................
Steering pump
Make and type ZF Unicorn .................................................................
Operating pressure: bar
Straight ahead at idle - max 7.0 .................................... 100
Full lock, left or right at idle - min 28 ............................. 400
Full lock, left or right at 1000 rev/min 70-77 ...................... 1000-1100
Steering geometery
Steering wheel diameter 412mm .................................................. 16.25 in
Steering column type Collapsible coupling .......................................................
Steering damper Double acting fitted between drag link and pinion ...............................................................
housing
Toe-out - measurement 0 to 2.0mm .................................................... 0 to 0.08 in
Toe-out - included angle 0
o
to 0
o
20 ..................................................
Camber angle 0
o
* ..................................................................
Castor angle 3
o
* .....................................................................
Swivel pin inclination 7
o
* ........................................................
* Check with vehicle in static unladen condition with
23 l, 6 US gal of fuel. Rock the vehicle up and down at
the front to allow the suspension to take an
unstressed position.
SUSPENSION
Type Coil springs controlled by telescopic dampers front .................................................................................
and rear.
Front Transverse location of axle by Panhard rod, and fore .................................................................................
and aft location by two radius arms. Anti-roll bar fitted.
Rear Fore and aft movement inhibited by two tubular trailing .................................................................................
links. Lateral location of axle by a centrally positioned
A frame, upperlink assembly, bolted at the apex to a
ball joint mounting. Anti-roll bar fitted.
Road spring data
90 model weight 2550 Kg ............................................................... 5622 lb
Front
Driver side NRC 9446 BLUE/GREEN ...............................................................
Passenger side NRC 9447 BLUE/YELLOW .......................................................
Rear
Driver side NRC 9448 RED/BLUE ...............................................................
Passenger side NRC 9449 YELLOW/WHITE .......................................................
04
8
INFORMATION
Shock absorbers
Type Telescopic, double-acting non-adjustable .................................................................................
Bore diameter 35.47mm ................................................................... 1.396 in
BRAKES
Front service brake
Caliper AP Lockheed, four opposed pistons ..............................................................................
Operation Hydraulic, self adjusting .........................................................................
Disc Ventilated, outboard ..................................................................................
Disc diameter 298mm ................................................................... 11.73 in
Disc thickness 24mm .................................................................. 0.945 in
Wear limit - per side of disc 1mm .............................................. 0.04 in
Disc run-out maximum 0.15mm ..................................................... 0.006 in
Pad area 58cm
2
.......................................................................... 9.0 in
2
Total swept area - per disc 801cm
2
............................................... 124 in
2
Pad material Ferodo 3440FM non asbestos .....................................................................
Pad minimum thickness 3mm ................................................... 0.12 in
Rear service brake
Caliper AP Lockheed opposed piston ..............................................................................
Operation Hydraulic, self adjusting .........................................................................
Disc Solid, outboard ..................................................................................
Disc diameter 290mm ................................................................... 11.42 in
Disc thickness 12.5mm .................................................................. 0.490 in
Wear limit - per side of disc 0.38mm .............................................. 0.015 in
Disc run-out maximum 0.15mm ..................................................... 0.006 in
Pad area 30.5cm
2
.......................................................................... 4.73 in
2
Total swept area - per disc 694cm
2
............................................... 106.98in
2
Pad minimum thickness 3mm ................................................... 0.12 in
Pad material Ferodo 3440FM non asbestos .....................................................................
Parking brake
Type Mechanical, cable operated drum brake on the rear of .................................................................................
the transfer gearbox output shaft
Drum internal diameter 254 mm ..................................................... 10.0 in
Width 70mm ................................................................................ 2.75 in
Pad material Ferodo 3611 non asbestos .....................................................................
Servo/master cylinder
Manufacturer Lucas ....................................................................
Servo type LSC 80, ratio 4.0:1 ........................................................................
Master cylinder tandem type - diameter 25.4 mm ........................... 1.0 in
Pressure reducing valve, failure conscious:
Cut-in pressure 24 bar ........................................................ 360 lbf/in
2
9
INFORMATION
AIR CONDITIONING
System CFC free expansion valve system .............................................................................
Compressor Nippon Denso 10PA17 .....................................................................
Refrigerant R134a .......................................................................
Charge quantity 900 gm 30 gm ....................................................... 32 oz 1 oz
Refrigerant oil 180 ml ................................................................... 6.3 oz
WIPER MOTORS
Windscreen wiper motor
Make/type Lucas 14W uprated two speed ........................................................................
Armature end float 0.1 to 0.2 mm ............................................................ 0.004 to 0.008 in
Brush length, minimum 4.8 mm .................................................... 0.20 in
Brush spring tension 140 to 200 g ........................................................ 5 to 7 oz
Resistance of armature winding at 16C, 68F
measured between adjacent commutatator segments 0.23 to 0.35 ohms .....
Light running, rack disconnected: current at 13.5 V 2.0 A .........
Wiper speed, wet screen, 60 seconds from cold:
Low speed 45 3 rev/min ...............................................................
High speed 65 5 rev/min ..............................................................
Tailgate wiper motor
Make/type IMOS (non-serviceable) ........................................................................
Running current, wet screen at 20C, 68F ambient 1.0 to 2.8 A ........
Wiper speed, wet screen at 20C, 68F ambient 37 to 43 cycles per minute .............
04
10
INFORMATION
ELECTRICAL
System 12 volt, negative ground .............................................................................
Battery
Make Land Rover Parts and Equipment ................................................................................
Lucas maintenance free
Type - standard 9-plate 371 .......................................................
Type - heavy duty 13-plate 389 ....................................................
Generator
Manufacturer Magnetti Marelli ....................................................................
Type A127 - 100amp .................................................................................
Polarity Negative ground .............................................................................
Brush length:
New 17 mm ......................................................................... 0.67 in
Worn, minimum free protrusion from moulding 5 mm ....... 0.20 in
Brush spring pressure flush with moulding 1.3 to 2.7N ...................... 0.25 to 0.60 lbf
Regulator voltage 13.6 to 14.4 volts .............................................................
Nominal output:
Generator speed 6000 rev/min .....................................................
Control at 14 V 65 A ........................................................
Starter motor
Make and type Magnetti Marelli M78R pre-engaged .................................................................
Brush spring tension 1020 gr ........................................................ 16 ozf
Brush minimum length 9.5 mm ..................................................... 0.07 in
Fuses
Type Autofuse (blade type) .................................................................................
Blow ratings to suit individual circuits
Horns
Make/type Klamix (Mixo) TR99 ........................................................................
11
INFORMATION
BULBS
Exterior Type
Headlamps 12V -60/55W Halogen .......................................................................
Front pilot lamps 12V -5W bayonet capless ...............................................................
Side marker lamps 12V -3.5W capless ...........................................................
Tail/Stop lamps 12V -5W/21W bayonet ................................................................
Stop lamps 12V -21W bayonet .......................................................................
High level stop lamp, soft top 12V -5W capless ...........................................
High level stop lamp, hard top 12V -21W bayonet ..........................................
Direction indicator lamps 12V -21W bayonet ..................................................
Number plate lamp 12V -5W capless ...........................................................
Reverse lamp 12V -21W bayonet ...................................................................
Rear fog guard lamp 12V -21W bayonet ........................................................
Interior Type
Interior roof lamps 12V -10W festoon ............................................................
Instrument illumination 12V -1.2W capless .....................................................
Warning light panel 12V -1.2W bulb/holder unit ..........................................................
Hazard warning switch 12V -1.2W capless .....................................................
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.
04
12
INFORMATION
VEHICLE WEIGHTS AND PAYLOAD
When loading a vehicle to its maximum Gross Vehicle Weight (GVW), consideration must be taken of the unladen
vehicle weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted
maximum values.
It is the customers responsibility to limit the vehicles payload in an appropriate manner such that neither
maximum axle loads nor GVW are exceeded.
VEHICLE CURB WEIGHTS
Curb weight = Vehicle weight + Full fuel tank (no occupants or pay load)
Soft top: 1710 Kg ............................................................................ 3768 lb
Hard top: 1770 kg .......................................................................... 3902 lb
Gross vehicle weight 2720 Kg ........................................................ 6001 lb
VEHICLE GROSS AXLE WEIGHTS
Front axle (GAWF) 1225 Kg ........................................................... 2701 lb
Rear axle (GAWR) 1495 kg ........................................................... 3300 lb
NOTE: Axle weights are not additve. The individual maximum axle weights and gross vehicle
weight must not be exceeded.
TOWING WEIGHTS
On-road Off-road
Unbraked trailers 750 Kg, 1653 lb .............................................................. 500 Kg, 1102 lb
Trailers with overrun brakes 3500 Kg, 8818 lb ............................................. 1000 Kg, 2204 lb
4 wheel trailers with coupled brakes * 4000 kg, 8818 lb .............................. 1000 kg, 2204 lb
Nose weight 160 kg, 350 lb ..................................................................... 160 kg, 350 lb
NOTE: * Only applies to vehicles modified to accept coupled brakes.
NOTE: All weight figures are subject to local restrictions.
13
INFORMATION
OFF-ROAD PERFORMANCE
Curb weight, full fuel tank and 75 kg, 150 lb:
Max. gradient 45 ...................................................................
Approach angle 51 ................................................................
Departure angle 35 ...............................................................
Wading depth 500 mm ................................................................... 20 in
Min. ground clearance (unladen): 229 mm .................................... 9.0 in
Ramp break over angle 146 ....................................................
NOTE: Departure angles do not account for the addition of a tow hitch.
04
14
INFORMATION
WHEELS AND TYRES
Wheel size - Alloy 7J X 16 .............................................................
Tyre size 265/75 - R16 MULTI-TERRAIN ..........................................................................
Tyre pressures:
Front Rear
Normal - all load conditions 265/75 R16 All Terrain ..............................................
Front 1,9 bar ................................ 28 lbf/in
2
Rear 2,4 bar ................................. 35 lbf/in
2
Soft ride* Front 1.6 bar ................................ 23 lbf/in
2
Rear 2,1 bar ................................. 30 lbf/in
2
* Soft ride pressure is for limitted use only and MUST
NOT be used above 55 mph, 85 km/h.
WARNING: Tyre pressures must be checked with the tyres cold, as the pressure is about 0.2 bar, 3
lbf/in
2
higher at running temperature. If the vehicle has been parked in the sun or high ambient
temperatures, DO NOT reduce the tyre pressures, move the vehicle into the shade and wait for the
tyres to cool before checking the pressures.
WARNING: Always use the same make and type of radial-ply tyres, front and rear. DO NOT use
cross-ply tyres, or interchange tyres from front to rear. If the wheel is marked TUBELESS, an
inner tube must NOT be fitted.
VEHICLE DIMENSIONS
Overall length:
Soft top 3722 mm .................................................................... 146.5 in
Hard top 3883 mm .................................................................. 152.9 in
Overall width (excluding mirrors): 1790 mm ..................................... 70.5 in
Overall height:
Soft top 1965 mm .................................................................... 77.4 in
Hard top 1972 mm .................................................................. 77.6 in
Wheelbase 2360 mm ....................................................................... 92.9 in
Track front/rear 1486 mm ................................................................. 58.5 in
Interior width between wheel boxes 925 mm ................................. 36.4 in
Turning circle 12.65m .................................................................... 41ft 6in
ENGINE TUNING DATA
1
INFORMATION
ENGINE 4.0 V8
Type 4.0 Litre V8 .................................................................................
Firing order 1-8-4-3-6-5-7-2 .....................................................................
Cylinder Numbers
Left bank 1-3-5-7 ..........................................................................
Right bank 2-4-6-8 ........................................................................
No 1 Cylinder location Pulley end of left bank ...................................................
Spark plugs
Make/type Champion RN11YCC ........................................................................
Gap 0.90 - 1.00 mm .................................................................................. 0.035 - 0.040 in
Coils
Make Lucas 2D1S2 ................................................................................
Type Double ended coil, bank of 4 .................................................................................
Compression ratio 9.35:1 - High Compression ............................................................
Fuel injection system
Make Sagem - Lucas ................................................................................
Type GEMS Sequential Multipoint Fuel injection (SFi) .................................................................................
Hot-wire air flow sensor system electronically
controlled
Valve Timing Inlet Exhaust
Opens 28BTDC .............................................................................. 66BBDC
Closes 77ABDC .............................................................................. 39ATDC
Duration 285 ........................................................................... 285
Valve peak 108ATDC ....................................................................... 110BTDC
Idle speed - controlled by GEMS system
All loads off 700 20 rev/min ..............................................................
Base idle speed Not adjustable ...............................................................
Idle air control valve position Checked via TestBook ...................................
CO at idle Less than 0.5% .........................................................................
Gasoline
9.35:1 - USA vehicles PREMIUM UNLEADED GASOLINE (PUG) .......................................................
with a CLC or AKI octane rating of 90 or 92.
GENERAL FITTING REMINDERS
1
INFORMATION
WORKSHOP SAFETY IS YOUR RESPONSIBILITY!
The suggestions, cautions and warnings in the
section are intended to serve as reminders for
trained and experienced mechanics. This manual
is not a defnitive guide to automotive mechanics
or workshop safety.
Shop equipment, shop environment, and the use
and disposal of solvents, fluids, and chemicals
are subject to government regulations which are
intended to provide a level of safety. It is your
responsibility to know and comply with such
regulations.
PRECAUTIONS AGAINST DAMAGE
1. Always fit covers to protect fenders before
commencing work in engine compartment.
2. Cover seats and carpets, wear clean overalls
and wash hands or wear gloves before working
inside vehicle.
3. Avoid spilling hydraulic fluid or battery acid on
paint work. Wash off with water immediately if
this occurs. Use Polythene sheets to protect
carpets and seats.
4. Always use a recommended Service Tool, or a
satisfactory equivalent, where specified.
5. Protect temporarily exposed screw threads by
replacing nuts or fitting plastic caps.
SAFETY PRECAUTIONS
1. Whenever possible, use a lift when working
beneath vehicle in preference to jacking. Chock
wheels as well as applying parking brake.
WARNING: Do not use a pit when
removing fuel system components.
2. Never rely on a jack alone to support vehicle.
Use axle stands carefully placed at jacking
points to provide rigid support.
3. Ensure that a suitable form of fire extinguisher is
conveniently located.
4. Check that any lifting equipment used has
adequate capacity and is fully serviceable.
5. Disconnect battery negative lead.
WARNING: Do not disconnect any pipes in
air conditioning system, unless trained
and instructed to do so. A refrigerant is
used which can cause blindness if allowed to
contact eyes.
6. Ensure that adequate ventilation is provided
when volatile degreasing agents are being used.
7. Do not apply heat in an attempt to free stiff
fixings; as well as causing damage to protective
coatings, there is a risk of damage to electronic
equipment and brake linings from stray heat.
07
2
INFORMATION
PREPARATION
1. Clean components and surrounding area prior to
removal. Before removing a component, clean it
and its surrounding areas as thoroughly as
possible.
2. Blank off any openings exposed by component
removal, using greaseproof paper and masking
tape.
3. Immediately seal fuel, oil or hydraulic lines when
separated, using plastic caps or plugs, to
prevent loss of fluid and entry of dirt.
4. Close open ends of oilways, exposed by
component removal, with tapered hardwood
plugs or readily visible plastic plugs.
5. Immediately a component is removed, place it in
a suitable container; use a separate container for
each component and its associated parts.
6. Before dismantling a component, clean it
thoroughly with a recommended cleaning agent;
check that agent is suitable for all materials of
component.
7. Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.
DISMANTLING
1. Observe scrupulous cleanliness when
dismantling components, particularly when
brake, fuel or hydraulic system parts are being
worked on. A particle of dirt or a cloth fragment
could cause a dangerous malfunction if trapped
in these systems.
2. Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
O-rings used for sealing are correctly replaced or
renewed, if disturbed.
3. Use marking ink to identify mating parts, to
ensure correct reassembly. If a centre punch or
scriber is used they may initiate cracks or
distortion of components.
4. Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
5. Wire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
6. Do not discard a part due for renewal until it has
been compared it with the new part, to ensure
the correct replacement has been obtained.
INSPECTION-GENERAL
1. Never inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an incipient
failure.
2. When a component is to be checked
dimensionally against figures quoted for it, use
correct equipment (surface plates, micrometers,
dial gauges, etc.) in serviceable condition.
Makeshift checking equipment can be
dangerous.
3. Reject a component if its dimensions are outside
limits quoted, or if damage is apparent. A part
may, however, be refitted if its critical dimension
is exactly limit size, and is otherwise satisfactory.
4. Use Plastigauge 12 Type PG-1 for checking
bearing surface clearances. Directions for its
use, and a scale giving bearing clearances in
0,0025 mm steps are provided with it.
3
INFORMATION
BALL AND ROLLER BEARINGS
CAUTION: Never refit a ball or roller
bearing without first ensuring that it is in a
fully serviceable condition.
1. Remove all traces of lubricant from bearing
under inspection by washing in a suitable
degreaser; maintain absolute cleanliness
throughout operations.
2. Inspect visually for markings of any form on
rolling elements, raceways, outer surface of
outer rings or inner surface of inner rings. Reject
any bearings found to be marked, since any
marking in these areas indicates onset of wear.
3. Holding inner race between finger and thumb of
one hand, spin outer race and check that it
revolves absolutely smoothly. Repeat, holding
outer race and spinning inner race.
4. Rotate outer ring gently with a reciprocating
motion, while holding inner ring; feel for any
check or obstruction to rotation, and reject
bearing if action is not perfectly smooth.
5. Lubricate bearing generously with lubricant
appropriate to installation.
6. Inspect shaft and bearing housing for
discoloration or other marking suggesting that
movement has taken place between bearing and
seatings. (This is particularly to be expected if
related markings were found in operation 2).
7. Ensure that shaft and housing are clean and free
from burrs before fitting bearing.
8. If one bearing assembly of a pair shows an
imperfection it is generally advisable to replace
both with new bearings; an exception could be
made if the faulty bearing had covered a low
mileage, and it could be established that
damage was confined to it only.
9. When fitting bearing to shaft, apply force only to
inner ring of bearing, and only to outer ring when
fitting into housing.
10. In the case of grease lubricated bearings (e.g.
hub bearings) fill space between bearing and
outer seal with recommended grade of grease
before fitting seal.
11. Always mark components of separable bearings
(e.g. taper roller bearings) in dismantling, to
ensure correct reassembly. Never fit new rollers
in a used outer ring, always fit a complete new
bearing assembly.
07
4
INFORMATION
OIL SEALS
NOTE: Ensure that the seal running track
is free from pits, scores, corrosion and
general damage prior to fitting
replacement seal.
1. Always fit new oil seals when rebuilding an
assembly.
2. Carefully examine seal before fitting to ensure
that it is clean and undamaged.
3. Coat the sealing lips with clean grease; pack
dust excluder seals with grease, and heavily
grease duplex seals in cavity between sealing
lips.
4. Ensure that seal spring, if provided, is correctly
fitted.
5. Place lip of seal towards fluid to be sealed and
slide into position on shaft, using fitting sleeve
when possible to protect sealing lip from damage
by sharp corners, threads or splines. If fitting
sleeve is not available, use plastic tube or tape
to prevent damage to sealing lip.
6. Grease outside diameter of seal, place square to
housing recess and press into position, using
great care and if possible a bell piece to ensure
that seal is not tilted. (In some cases it may be
preferable to fit seal to housing before fitting to
shaft). Never let weight of unsupported shaft rest
in seal.
7. If correct service tool is not available, use a
suitable drift approximately 0.4mm (0.015 in)
smaller than outside diameter of seal. Use a
hammer VERY GENTLY on drift if a press is not
suitable.
8. Press or drift seal in to depth of housing if
housing is shouldered, or flush with face of
housing where no shoulder is provided. Ensure
that the seal does not enter the housing in a
tilted position.
NOTE: Most cases of failure or leakage of
oil seals are due to careless fitting, and
resulting damage to both seals and
sealing surfaces. Care in fitting is essential if
good results are to be obtained. NEVER use a seal
which has been improperly stored or handled,
such as hung on a hook or nail.
5
INFORMATION
JOINTS AND JOINT FACES
1. Always use correct gaskets where they are
specified.
2. Use jointing compound only when
recommended. Otherwise fit joints dry.
3. When jointing compound is used, apply in a thin
uniform film to metal surfaces; take great care to
prevent it from entering oilways, pipes or blind
tapped holes.
4. Remove all traces of old jointing materials prior
to reassembly. Do not use a tool which could
damage joint faces.
5. Inspect joint faces for scratches or burrs and
remove with a fine file or oil stone; do not allow
removed material or dirt to enter tapped holes or
enclosed parts.
6. Blow out any pipes, channels or crevices with
compressed air, fit new O rings or seals
displaced by air blast.
FLEXIBLE HYDRAULIC PIPES, HOSES
1. Before removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
2. Obtain appropriate plugs or caps before
detaching hose end fittings, so that ports can be
immediately covered to exclude dirt.
3. Clean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any hose found faulty.
4. When refitting hose, ensure that no unnecessary
bends are introduced, and that hose is not
twisted before or during tightening of union nuts.
5. Containers for hydraulic fluid must be kept
absolutely clean.
6. Do not store brake fluid in an unsealed
container. It will absorb water, and fluid in this
condition would be dangerous to use due to a
lowering of its boiling point.
7. Do not allow brake fluid to be contaminated with
mineral oil, or use a container which has
previously contained mineral oil.
8. Do not re-use brake fluid bled from system.
9. Always use clean brake fluid to clean hydraulic
components.
10. Fit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of dirt.
11. Absolute cleanliness must be observed with
hydraulic components at all times.
12. After any work on hydraulic systems, inspect
carefully for leaks underneath the vehicle while a
second operator applies maximum pressure to
the brakes (engine running) and operates the
steering.
07
6
INFORMATION
FUEL SYSTEM HOSES
CAUTION: All fuel hoses are made up of
two laminations, an armoured rubber outer
sleeve and an inner viton core. If any of
the fuel system hoses have been disconnected, it
is imperative that the internal bore is inspected to
ensure that the viton lining has not become
separated from the amoured outer sleeve. A new
hose must be fitted if separation is evident.
METRIC BOLT IDENTIFICATION
1. An ISO metric bolt or screw, made of steel and
larger than 6 mm in diameter can be identified by
either of the symbols ISO M or M embossed or
indented on top of the head.
2. In addition to marks to identify the manufacture,
the head is also marked with symbols to indicate
the strength grade, e.g. 8.8, 12.9 or 14.9, where
the first figure gives the minimum tensile
strength of the bolt material in tens of kgf/mm
2
.
3. Zinc plated ISO metric bolts and nuts are
chromate passivated, a gold-bronze colour.
METRIC NUT IDENTIFICATION
1. A nut with an ISO metric thread is marked on
one face or on one of the flats of the hexagon
with the strength grade symbol 8, 12 or 14.
Some nuts with a strength 4, 5 or 6 are also
marked and some have the metric symbol M on
the flat opposite the strength grade marking.
2. A clock face system is used as an alternative
method of indicating the strength grade. The
external chamfers or a face of the nut is marked
in a position relative to the appropriate hour
mark on a clock face to indicate the strength
grade.
3. A dot is used to locate the 12 oclock position
and a dash to indicate the strength grade. If the
grade is above 12, two dots identify the 12
Oclock position.
KEYS AND KEYWAYS
1. Remove burrs from edges of keyways with a fine
file and clean thoroughly before attempting to
refit key.
2. Clean and inspect key closely; keys are suitable
for refitting only if indistinguishable from new, as
any indentation may indicate the onset of wear.
TAB WASHERS
1. Fit new washers in all places where they are
used. Always fit a new tab washer.
2. Ensure that the new tab washer is of the same
design as that replaced.
7
INFORMATION
COTTER PINS
1. Fit new cotter pins throughout when replacing
any unit.
2. Always fit cotter pins where cotter pins were
originally used. Do not substitute spring
washers: there is always a good reason for the
use of a cotter pin.
3. All cotter pins should be fitted as shown unless
otherwise stated.
NUTS
1. When tightening a slotted or castellated nut
never loosen it to insert cotter pin or locking wire
except in those recommended cases where this
forms part of an adjustment. If difficulty is
experienced, alternative washers or nuts should
be selected, or washer thickness reduced.
2. Where self-locking nuts have been removed it is
advisable to replace them with new ones of the
same type.
NOTE: Where bearing pre-load is involved
nuts should be tightened in accordance
with special instructions.
LOCKING WIRE
1. Fit new locking wire of the correct type for all
assemblies incorporating it.
2. Arrange wire so that its tension tends to tighten
the bolt heads, or nuts, to which it is fitted.
SCREW THREADS
1. Both UNF and Metric threads to ISO standards
are used. See below for thread identification.
2. Damaged threads must always be discarded.
Cleaning up threads with a die or tap impairs the
strength and closeness of fit of the threads and
is not recommended.
3. Always ensure that replacement bolts are at
least equal in strength to those replaced.
4. Do not allow oil, grease or jointing compound to
enter blind threaded holes. The hydraulic action
on screwing in the bolt or stud could split the
housing.
5. Always tighten a nut or bolt to the recommended
torque value. Damaged or corroded threads can
affect the torque reading.
6. To check or re-tighten a bolt or screw to a
specified torque value first loosen a quarter of a
turn, then re-tighten to the correct value.
7. Oil thread lightly before tightening to ensure a
free running thread, except in the case of
threads treated with sealant/lubricant, and
self-locking nuts.
07
8
INFORMATION
UNIFIED THREAD IDENTIFICATION
1. Bolts
A circular recess is stamped in the upper surface
of the bolt head.
2. Nuts
A continuous line of circles is indented on one of
the flats of the hexagon, parallel to the axis of
the nut.
3. Studs, Brake Rods, etc.
The component is reduced to the core diameter
for a short length at its extremity.
LUBRICANTS, FLUIDS AND CAPACITIES
1
INFORMATION
RECOMMENDED LUBRICANTS AND FLUIDS
AMBIENT TEMPERATURE C
COMPONENT SPECIFICATION VISCOSITY -30 -20 -10 0 10 20 30 40 50
Engine V8i Use oils to API 5W/20
service level
SG, SH 5W/30
or 5W/40
RES.22.OL.G4
or
ACEA A2:96 10W/30
10W/40
10W/50
15W/40
15W/50
20W/40
20W/50
Automatic gearbox ATF Dexron IID
Final drive units API or GL5 90 EP
Swivel pin
housings*
MIL - L - 2105 or
MIL - L - 2105B, C
or D 80W EP
LT 230 API GL4 or GL5 90 EP
transfer gearbox MIL - L - 2105 or
MIL - L - 2105B
Power steering ATF Dexron IID
Brake reservoir Brake fluid must have a minimum
boiling point of 260C (500F) and
comply with FMVSS/116/DOT 4
Lubrication nipples
(hubs, ball joints,
etc.)
NLGI-2 multipurpose lithium based
grease
* Swivel pin housings with filler, level and drain plugs.
See table on page 2 for remaining vehicle components
09
2
INFORMATION
Swivel pin housings
**
Molytex EP 00 GREASE to specification XP153
Propeller shaft Front
and Rear
NLGI - 2 Multi-purpose Lithium based GREASE
Lubrication nipples
(hubs, ball joints
etc.)
Seat slides
Door lock striker
Brake reservoir Brake fluids having a minimum boiling point of 260C (500F) and complying with
FMVSS 116 DOT4
Engine coolant Use an ethylene glycol based anti-freeze (containing no methanol)
V8i (aluminium) with non-phosphate corrosion inhibitors suitable for use in aluminium engines to ensure
the protection of the cooling system against frost and corrosion in all seasons. Use one
part anti-freeze to one part water for protection down to -36C (-33F).
IMPORTANT: Coolant solution must not fall below proportions one part
anti-freeze to three parts water, i.e. minimum 25% anti-freeze in coolant otherwise
damage to engine is liable to occur. Or a maximum of 60%.
Battery lugs, Petroleum jelly.
Earthing surfaces NOTE: Do not use Silicone Grease
where paint has
been removed
Air Conditioning
System Refrigerant Use only refrigerant R134a
Compressor Oil Nippon Denso ND-OIL8 Unipart ND-OIL8
Speed sensor Silicone grease: Staborags NBU - Wabco 830 502,0634
bush-rear Wacker chemie 704 - Wabco 830 502,0164
Kluber GL301
** Swivel pin housings having a filler plug only.
LUBRICATION PRACTICE
Use a high quality oil of the correct viscosity range and service classification in the engine during maintenance and
when topping up. The use of oil not to the correct specification can lead to high oil and fuel consumption and
ultimately to damaged components.
Oil to the correct specification contains additives which disperse the corrosive acids formed by combustion and
prevent the formation of sludge which can block the oilways. Additional oil additives should not be used. Always
adhere to the recommended servicing intervals.
WARNING: Many liquids and other substances used in motor vehicles are poisonous. They must
not be consumed and must be kept away from open wounds. These substances, among others,
include anti-freeze windscreen washer additives, lubricants and various adhesives.
3
INFORMATION
CAPACITIES
The following capacity figures are approximate and are provided as a guide only.
Capacities (approx.) Litres US unit
Fuel tank usable fuel 59 ........................................................ 15.6 gall
Engine sump oil - V8i 6.0 ....................................................... 6.5 quarts
-Extra after fitting new filter 0,6 ..................................... 1.2 pt
Automatic gearbox * 9,1 ......................................................... 9.6 quarts
Transfer gearbox oil 2,3 ......................................................... 4.8 pt
Front differential 1,7 ............................................................... 3.6 pt
Rear differential 2.3 ................................................................ 4.8 pt
Power steering box and reservoir 2,9 .................................... 6.0 pt
Swivel pin housing oil / grease (each) ** 0,35 .......................... 0.75 pt
Cooling system 12.8 ................................................................ 13.5 quarts
Washer bottle 3,0 ................................................................... 6.0 pt
NOTE: All levels must be checked by dipstick or level plugs as applicable.
* When draining fluid from the ZF automatic gearbox, fluid will remain in the torque converter, refill
to high level on dipstick only.
** Swivel pin housings with a filler plug only must be filled with GREASE.
09
4
INFORMATION
ANTI-FREEZE
ENGINE TYPE MIXTURE STRENGTH PERCENTAGE PROTECTION
CONCENTRATION LOWER
TEMPERATURE
LIMIT
V8i Engine One part anti-freeze
One part water 50%
Complete protection - 33F
Vehicle may be driven away immediately from cold - 36C
Safe limit protection - 41C
Coolant in mushy state. Engine may be started and driven away after warm-up
period
- 42F
Lower protection - 47C
Prevents frost damage to cylinder head, block and radiator. Thaw out before
starting engine
- 53F
CAUTION: Anti-freeze content must never be allowed to fall below 25% otherwise damage to the
engine is liable to occur. Also, anti-freeze content should not exceed 60% as this will greatly
reduce the cooling effect of the coolant.
RECOMMENDED FUEL
Petrol engines
- with catalytic converter UNLEADED ONLY USA 90 CLC or 92 AKI ................
Catalyst vehicles
Vehicles equipped with catalytic converter are
designed to use ONLY unleaded fuel. Unleaded fuel
must be used for the emission control system to
operate properly. Its use will also reduce spark plug
fouling, exhaust system corrosion and engine oil
deterioration.
Using fuel that contains lead will result in damage to
the emission control system and could result in loss of
warranty coverage. The effectiveness of the catalysts
in the catalytic converters will be seriously impaired if
leaded fuel is used. The vehicle is equipped with an
electronic fuel injection system, which includes four
oxygen sensors. Leaded fuel will damage the sensors,
and will deteriorate the emission control system.
Regulations require that pumps delivering unleaded
fuel be labelled UNLEADED. Only these pumps have
nozzles which fit the filler neck of the vehicle fuel tank.
MAINTENANCE
1
MAINTENANCE
SERVICE SCHEDULE
This section gives information on the range of service
procedures.
Where required, instructions are given for carrying out
each service procedure, or a cross reference is given,
where the procedure can be found in this manual.
Service Schedule sheets are published separately to
reflect the maintenance needs and intervals for each
vehicle variant and model year. The procedures given
must be used in conjunction with the Service
Schedule sheets.
VEHICLE INTERIOR
CHECK SEATS & BELTS
Check condition and security of seats, seat belt
mountings, seat belts, buckles and opertion of inertia
seat belts.
Lubricate seat tilt pivots.
CHECK OPERATION OF FOOT BRAKE
If pedal feels spongy bleed system. See BRAKES,
Repair, Brake System Bleed
Check all hoses and pipes for security, fractures and
leaks. Fit new hoses and pipes as necessary.
CHECK OPERATION OF LAMPS
Check operation of all lamps, horns and warning
indicators.
CHECK OPERATION OF WIPERS
Check operation of front/rear screen wipers and
washers and condition of wiper blades.
10
MAINTENANCE
2
MAINTENANCE
CLEAN BATTERY TERMINALS
1. Remove LH front seat cushion.
2. Release retaining clip and remove battery
access cover.
3. Disconnect both battery leads, negative - first.
Clean off corrosion and neutralize. Smear
terminals with petroleum jelly.
4. Reconnect battery leads, positive first, when
maintenace operations have been completed.
5. Fit battery access cover and LH front seat
cushion.
A low maintenance battery is fitted as original
equipment. Dependent upon climatic conditions
electrolyte levels should be checked as follows:
Temperate climates every 3 years.
Hot climates every year.
CHECK/ADJUST OPERATION OF PARK BRAKE
Park brake check
1. Check park brake is fully operational on third
notch of ratchet. Readjust if necessary.
Park brake adjust
1. Select P in main gearbox and chock road
wheels.
2. Raise one rear wheel clear of ground and supprt
securely with axle stand.
3. Release park brake lever.
4. Underneath vehicle, rotate brake adjuster
clockwise to 25 Nm, 18 lbf ft to fully expanded
shoes against drum.
5. Back off adjuster by 1 turns, check that drum
is free to rotate.
6. Adjust park brake cable locknuts to give pawl 2
notches free movement on ratchet before being
fully operational on third notch of ratchet.
CAUTION: Cable adjustment must ONLY
be used for initial setting and to
compensate for cable stretch. It MUST
NOT be used to take up brake shoe wear, which
MUST be adjusted at brake drum.
7. Operate parking brake to settle shoes. Recheck
park brake is fully operational on third notch of
ratchet. Readjust if necessary.
8. Remove axle stand and wheel chocks.
MAINTENANCE
3
MAINTENANCE
VEHICLE EXTERIOR
CHECK/ADJUST HEADLAMP ALIGNMENT
Check/adjust headlamp and auxiliary alignment.
REMOVE WHEELS, CHECK TYRES
Check tyres (including spare) for compliance with
manufacturers specification.
Check visually for cuts, lumps, bulges, uneven tread
wear and tread depth. Check road wheels for
damage.
Check/adjust tyre pressures.
INSPECT BRAKE PADS FOR WEAR, CALIPERS
FOR LEAKS AND CONDITION
Check thickness of brake pads, fit new pads if
minimum thickness is less than 3,0mm, 0.12 in. Check
brake pads for oil contamination. If new brake pads
required. See BRAKES, Repair, Front Brake Pads
or. See BRAKES, Repair, Rear Brake Pads
WARNING: When renewing brake pads, it
is essential that only genuine components
with correct grade of lining are used.
Always fit new pads as complete axle sets, NEVER
individually or as a single wheel set. Serious
consequences could result from out of balance
braking due to mixing of linings.
Refit road wheels
Fit road wheels in original hub position. Secure in
position with wheel nuts, do not fully tighten wheel
nuts at this stage, lower vehicle and finally tighten
wheel nuts to correct torque.
Alloy wheels: 130 Nm, 95 lbf ft.
CHECK FRONT WHEEL ALIGNMENT
Use recognised wheel alignment equipment to
perform this check and adjustment. See STEERING,
Adjustment, Front Wheel Alignment
LUBRICATE ALL HINGES, DOOR CHECK
MECHANISMS, BONNET [HOOD] CATCHES AND
FUEL FILLER FLAP
CHECK OPERATION OF ALL DOOR, BONNET
[HOOD] AND TAILDOOR LOCKS
CHECK/TIGHTEN TOWING BRACKET FITTINGS
10
MAINTENANCE
4
MAINTENANCE
UNDER BONNET [HOOD] MAINTENANCE
CHECK COOLING/HEATER SYSTEMS
Check cooling/heater systems for leaks and hoses for
security and condition.
Cooling system hoses should be changed at first
signs of deterioration.
CHECK CONDITION OF ENGINE MOUNTING
RUBBERS
CHECK BRAKE SERVO HOSE FOR SECURITY
AND CONDITION
CHECK FUEL EVAPORATIVE LOSS CONTROL
SYSTEM FOR LEAKS
CHECK FUEL FILLER CAP SEAL FOR LEAKS
CHECK IGNITION WIRING
Check H.T. leads for fraying, chafing and
deterioration. Ensure H.T. leads are correctly clipped
in place.
MAINTENANCE
5
MAINTENANCE
RENEW SPARK PLUGS - V8i
Clean, adjust and renew
1. Take great care when fitting spark plugs not to
cross-thread plug, otherwise costly damage to
cylinder head will result.
2. Clean or replace spark plugs as applicable.
3. It is essential that correct type of spark plugs are
fitted.
4. Incorrect grade of plugs may lead to piston
overheating and engine failure.
Remove
5. Disconnect battery negative lead. Disconnect
H.T. leads from spark plugs.
6. Remove plugs and washers.
Refit
7. Inspect spark plugs, renew as necessary.
8. Set plug gaps.
CAUTION: Use correct type and grade of
plug.
9. Apply anti-seize to plug threads. Fit spark plugs.
Tighten to 20Nm, 15 lbf ft.
10. Connect and route spark plug leads correctly.
Failure to route H.T. leads correctly may result in
cross-firing between two closely fitted leads
which are consecutive in firing order.
CAUTION: When pushing leads onto
plugs, ensure that shrouds are firmly
seated.
CLEAN PLENUM CHAMBER VENTILATION
PASSAGEWAY - V8i
CAUTION: Care must be taken to prevent
debris from passageway passing beyond
throttle butterfly disc.
WARNING: Safety glasses must be worn
when performing this operation. Ensure
that debris is not blown into atmosphere
which could be harmful to other persons closeby.
2. Release hose clamp and remove hose from
plenum chamber inlet.
3. Remove crankcase ventilation hose from side of
plenum chamber.
4. Insert a piece of lint free cloth down throttle
butterfly bore to prevent debris passing throttle
butterfly.
5. Place a cloth over tube protruding from side of
plenum from which ventilation hose was
removed to prevent debris from passageway
being blown into atmosphere.
10
MAINTENANCE
6
MAINTENANCE
6. Use a compressed air line with a slim bent
nozzle to enable passageway to be cleaned out
from within throttle butterfly bore.
7. Any remaining matter can be dislodged using
soft bent wire or pipe cleaner. Finally blow out
passageway again to remove remaining debris.
8. Remove small T piece between crankcase
ventilation hoses and check it is free from
blockages, clean as necessary.
9. Refit T piece and hoses, tighten hose clamps
securely.
RENEW AIR CLEANER ELEMENT - V8i
To renew air cleaner element - V8i
See FUEL SYSTEM, Repair, Air Cleaner
RENEW CHARCOAL CANISTER AND PURGE
CONTROL VALVE - V8i
Renew charcoal canister and purge control valve.
See EMISSION CONTROL, Repair, EVAP canister
and purge control valve
CHECK AUXILIARY DRIVE BELT - V8i
1. Check condition of drive belt, renew a belt that
shows signs of wear, splitting or oil
contamination.
2. Check belt length indicator, belt MUST be
renewed before indicator reaches RH end of
slot.
RENEW AUXILIARY DRIVE BELT - V8i
Renew drive belt. See ELECTRICAL, Repair,
Auxiliary drive Belt
CHECK/TOP-UP AUTOMATIC TRANSMISSION
FLUID LEVEL
NOTE: Transmission fluid level is checked
when fluid is cold with engine idling in N
(neutral).
1. Ensure vehicle is on level ground.
2. Check fluid level registers between the 2 level
marks on dipstick.
3. Top-up to high mark on dipstick using the correct
grade of transmission fluid. See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
recommended lubricants and fluids
MAINTENANCE
7
MAINTENANCE
CHECK/TOP-UP COOLING SYSTEM
To prevent corrosion of aluminium alloy engine parts it
is imperative that cooling system is filled with a
solution of water and phosphate free anti-freeze, at all
times. Never fill or Top-up with plain water.
WARNING: Do not remove filler cap when
engine is hot because cooling system is
pressurised and personal scalding could
result.
1. First turn filler cap slowly counter-clockwise to its
stop, pause and allow all pressure to escape.
Press down and continue to turn until cap is
removed.
2. When engine is cold, expansion tank should be
approximately half full with coolant
3. If necessary, Top-up cooling system with
premixed coolant. Use soft water whenever
possible, if local water supply is hard, rainwater
should be used.
4. When replacing filler cap it is important that it is
tightened down fully. Failure to tighten filler cap
properly may result in water loss, with possible
damage to engine
The cooling system should be drained and flushed at
2 year intervals or at onset of second winter. Refer to
Coolant Requirements. See COOLING SYSTEM,
Adjustment, Coolant Requirements
CHECK/TOP-UP POWER STEERING FLUID
RESERVOIR
1. Clean area of fluid reservoir cap and remove
cap.
2. Check that fluid level is not below lower mark on
dipstick.
3. Top-up to high mark on dipstick using
transmission fluid. See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
10
MAINTENANCE
8
MAINTENANCE
CHECK/ TOP-UP BRAKE FLUID RESERVOIR
CAUTION: Brake fluid can damage
paintwork. If spillage occurs, wash
affected area IMMEDIATELY with a large
quantity of water.
1. Clean area of filler cap and side of reservoir.
2. Check fluid level in reservoir by observing level
through translucent side. Level must be above
MIN mark.
CAUTION: If level is below MIN mark,
check braking system for possibility of
fluid leakage.
3. Remove filler cap and top-up to MAX mark with
NEW brake fluid of the correct specification from
a sealed container. See LUBRICANTS,
4. Refit filler cap.
CHECK/TOP-UP WASHER RESERVOIR
Top-up washer reservoir to within 25 mm, 1.0 in of
filler neck. Use a screen washer solvent/anti-freeze
solution to assist removing mud, flies and road film
and protect against freezing.
CHECK/ADJUST STEERING BOX
1. Check steering box for fluid leaks.
2. Check that there is no backlash in steering box
in straight ahead position. Adjust steering box if
necessary. See STEERING, Adjustment,
Power Steering Box - adjust
MAINTENANCE
9
MAINTENANCE
UNDER VEHICLE MAINTENANCE
Vehicles operating under severe conditions of dust,
sand, mud or water should have oils changed and
lubrication carried out at more frequent intervals than
is recommended in maintenance schedules.
RENEW ENGINE OIL AND FILTER - V8i
1. Ensure vehicle is level. If necessary, run engine
to warm oil.
2. Disconnect battery. See Clean battery terminals.
3. Place drain tray under drain plug.
4. Remove engine oil dipstick.
5. Remove sump drain plug. Allow oil to drain
completely.
6. Fit NEW copper washer and refit drain plug. 43
Nm, 32 lbf ft.
7. Place drain tray under filter.
8. Unscrew oil filter counter-clockwise.
9. Clean filter adaptor face. Coat sealing ring on
NEW filter with clean engine oil. Screw filter on
until sealing ring contacts sealing face (finger
tight), then tighten a further half turn by hand
only. DO NOTovertighten.
10. Remove engine oil filler cap. Clean inside and
outside of cap.
11. Pour in correct quantity of NEW oil to FULL
mark on dipstick. See LUBRICANTS, FLUIDS
12. Reconnect battery, run engine and check for oil
leaks from oil filter.
13. Stop engine, allow oil to return to sump for a few
minutes, then recheck oil level and top-up if
necessary.
NOTE: Oil can symbol on dipstick must be
correct way up when viewed from LH side
of vehicle.
10
MAINTENANCE
10
MAINTENANCE
RENEW AUTOMATIC GEARBOX FLUID AND
FLUID SCREEN - ZF
1. Ensure vehicle is level. Place drain tray under
drain plug.
2. Remove gearbox dipstick, located at rear of RH
rocker cover, to aid oil drainage. Remove drain
plug from bottom of sump and allow fluid to drain
completely.
3. Refit plug using a NEW sealing washer. Tighten
to 10 Nm, 8 lbf ft.
4. Remove and replace fluid screen. See
AUTOMATIC GEARBOX, Repair, Fluid Pan
Gasket and Screen
Refill and Check Fluid Level.
NOTE: The fluid level must checked when
fluid is COLD and engine idling in N.
5. Refill or top-up with correct quantity and grade of
fluid. See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, recommended
lubricants and fluids
6. With P selected, start and run engine. Apply
footbrake, move selector slowly to position 1
then back to N. Check fluid level, this must be
between the 2 level marks on dipstick.
MAINTENANCE
11
MAINTENANCE
CHECK/TOP-UP TRANSFER GEARBOX OIL
1. Ensure vehicle is level.
3. Clean area around filler/level plug.
4. Remove plug and fill gearbox with recommended
grade of oil, until oil starts to seep from filler/level
hole. See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, recommended
5. Clean any previously applied sealant from
filler/level plug.
6. Apply Hylomar sealant to threads of plug and
refit plug. Tighten to 30 Nm, 22 lbf ft.
7. Wipe away any surplus oil.
8. Reconnect battery negative lead.
RENEW TRANSFER GEARBOX OIL
3. Clean area around filler/level and drain plugs.
WARNING: When draining gearbox care
should be taken to ensure that oil is not
hot as personal scalding could result.
4. Place a suitable container under transfer
gearbox.
5. Remove filler/level plug to vent gearbox and
assist draining.
6. Remove drain plug and allow oil to drain.
7. Thoroughly clean drain plug threads prior to
applying fresh Hylomar sealant. Fit plug
Tighten to 30 Nm, 22 lbf ft.
8. Fill gearbox with correct quantity and grade of oil
until oil seeps from filler level hole. Wipe away
any surplus oil. See LUBRICANTS, FLUIDS
Recommended lubricants and fluids
9. Thoroughly clean filler/level plug threads prior to
applying fresh Hylomar sealant. Fit plug
Tighten to 30 Nm, 22 lbf ft.
10
MAINTENANCE
12
MAINTENANCE
CHECK/TOP-UP FRONT AND REAR AXLE OIL
2. Using a 13mm, 0.5 in square drive wrench,
remove filler/level plug from axle.
3. If necessary inject oil of recommended grade
until it reaches level hole. See LUBRICANTS,
4. Clean and refit filler/level plug and wipe away
surplus oil.
RENEW FRONT AND REAR AXLE OIL
1. Site vehicle on lift or level ground. Place
container under axle to be drained.
2. Using a 13mm, 0.5 in square drive wrench,
remove drain and filler/level plugs from axle.
Allow oil to drain completely. Clean and refit
drain plug.
3. Inject new oil of recommended make and grade
until it reaches level hole. See LUBRICANTS,
4. Clean and refit filler/level plug and wipe away
surplus oil.
CHECK/TOP-UP SWIVEL PIN HOUSING OIL
CAUTION: Housings with filler plug only
are filled with grease which does not
require top-up or renewing.
1. Site vehicle on lift or level ground. Clean area of
filler/level plug.
2. Remove filler/level plug and inject recommended
grade of oil until it seeps from level hole.
3. Refit filler/level plug, wipe away any surplus oil.
RENEW SWIVEL PIN HOUSING OIL
1. Site vehicle on lift or level ground. Place
container under swivel to be drained.
2. Remove drain and level plugs, allow oil to drain
completely, clean and refit drain plug.
3. Remove filler plug and inject recommended
grade of oil it reaches level hole.
4. Clean and refit level and filler plugs, wipe away
any surplus oil.
NOTE: On later vehicles, the level and
drain plugs have been deleted. The swivel
pin housing is filled with grease for life
service and maintenance is not required.
MAINTENANCE
13
MAINTENANCE
LUBRICATE PROPELLER SHAFT SLIDING AND
UNIVERSAL JOINTS
1. Clean all grease nipples on front and rear
propeller shafts.
2. Using a low pressure hand grease gun, apply
recommended grease, to grease nipples at front
and rear propeller shaft universal and sliding
joints.
CHECK VISUALLY BRAKE, FUEL PIPES/UNIONS
FOR CHAFING LEAKS AND CORROSION
CHECK EXHAUST SYSTEM FOR LEAKS,
SECURITY AND DAMAGE
CHECK FOR FLUID LEAKS FROM POWER
STEERING AND SUSPENSION SYSTEMS,
HYDRAULIC PIPES AND UNIONS FOR CHAFING
AND CORROSION
CHECK/TIGHTEN STEERING UNIT AND STEERING
ROD BALL JOINT FIXINGS, CHECK CONDITION
OF OF BALL JOINTS AND DUST COVERS
Ball joints are lubricated for their normal life during
manufacture and require no further lubrication. This
applies ONLY if rubber boot has not been dislodged
or damaged. Joints should be checked at specified
mileage intervals but more frequently if vehicle is used
under arduous conditions.
1. Check for wear in joints by moving ball joint up
and down vigorously. If free movement is
apparent fit a new joint assembly.
CHECK/TIGHTEN FRONT AND REAR AXLE
SUSPENSION LINK FIXINGS, CHECK CONDITION
OF MOUNTING RUBBERS.
CHECK/TIGHTEN TOWING BRACKET FIXINGS.
10
MAINTENANCE
14
MAINTENANCE
RENEW FUEL FILTER
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction are strictly adhered to when
carrying out following instructions. See
INTRODUCTION, Information, Fuel Handling
Precautions
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
The fuel line filter is located on RH chassis side
member forward of the rear wheel arch.
2. Thoroughly clean area around hose
connections.
3. Position cloth around relevant union on fuel filter
to protect against fuel spray as fuel line pressure
is released. See FUEL SYSTEM, Repair, Fuel
filter
4. Loosen 2 fuel unions and disconnect hoses from
filter canister.
5. Loosen bolt securing bracket to chassis side
member and remove filter.
Fit new filter
6. Fit a new filter and tighten bracket bolt. Ensure
direction of flow ARROW on canister faces
forward.
7. Fit inlet and outlet hoses. 30 Nm, 22 lbf ft.
9. Start engine and inspect hose connections for
fuel leaks.
RENEW HEATED OXYGEN SENSORS (HO2S)
See FUEL SYSTEM, Repair, Heated Oxygen
Sensor (HO2S) - Front
and
See FUEL SYSTEM, Repair, Heated Oxygen
Sensor (HO2S) - Rear
RENEW CATALYTIC CONVERTERS
See EMISSION CONTROL, Repair, front pipe /
catalytic converter
REPORT ANY UNUSUAL FEATURES OF VEHICLE
CONDITION AND ADDITIONAL WORK REQUIRED
MAINTENANCE
15
MAINTENANCE
CARRY OUT ROAD OR ROLLER TEST
WARNING: Two wheel roller tests must be
restricted to 8 mph, 5km/hour. Do not
engage the differential lock or the vehicle
will drive off the test rig because the vehicle is in
permanent four wheel drive.
For details of dynamometer testing. See
INTRODUCTION, Information, Dynamometer
Testing
Check following items:
1. Inhibitor switch only operates in P and N.
2. Engine for excessive noise.
3. Automatic gear selection/shift speeds.
4. Gear selection/noise - high/low range.
5. Steering for abnormal noise/effort.
6. Steering for free play.
7. All instruments, gauges and warning indicators.
8. Heater and air conditioning systems.
9. Heated rear screen.
10. Shock absorbers - ride irregularities.
11. Foot brake, on emergency stop, pulling to one
side, binding, pedal effort.
12. Park brake operation.
13. Seat reclining and latching.
14. Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
15. Road wheel balance.
16. Transmission for vibrations.
17. Body noises, squeaks and rattles.
18. Excessive exhaust smoke.
19. Engine idle speed.
20. Endorse service record.
21. Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORD
RESET EMISSION MAINTENANCE REMINDER -
USA
The emission maintenance reminder is designed to
activate at 82,500 and 165,000 miles respectively and
will illuminate a Service Engine RED warning light in
instrument binnacle.
The emission maintenance reminder must be reset
after required maintenance has been carried out and
a new tamperproof label fitted by a Land Rover of
North America dealer. This emission maintenance
reminder is part of the Emission Control System
Reset
1. The control unit is located in the passenger
footwell.
2. Identify control unit and remove from plug.
3. Remove tamperproof label to reveal access hole
for resetting.
4. Place a thin metallic probe into access hole and
momentarily electrically short between reset pins
inside unit.
RECOMMENDED SERVICE ITEMS
Refer Service Schedule sheets for intervals.
Clean sunroof drain tubes, clean and lubricate guide
rails and slides.
Renew the hydraulic brake fluid. See BRAKES,
Repair, Brake System Bleed
Renew all hydraulic brake fluid, seals, brake servo
filter and flexible hoses.
All working surfaces of the master cylinder and caliper
cylinders should be examined and renewed where
necessary.
Air cleaner - When the vehicle is used in dusty or field
conditions or deep wading, frequent attention to the
air cleaner may be required.
MAINTENANCE
1
SPECIFICATIONS, TORQUE
TORQUE SETTINGS
Nm lbf ft
Road wheel nuts 130 .............................................................. 95
Spark plugs 20 ...................................................................... 15
Automatic gearbox drain plug 10 .......................................... 8
Transfer box drain/filler plugs 30 ........................................... 22
Fuel filter hose/pipe unions 30 .............................................. 22
Steering box drop arm nut 175 ................................................ 130
Steering box to chassis 80 .................................................... 60
Steering box tie-rod 80 .......................................................... 60
Front radius arm to chassis 200 .............................................. 150
Rear radius arm to axle 175 .................................................... 130
Bottom link to axle/chassis 175 ............................................... 130
4.0 V8
1
REPAIR
CRANKSHAFT REAR OIL SEAL
Service repair no - 12.21.20
Remove
2. Remove drive plate. See ENGINE 4.0 V8,
Repair, Drive Plate
3. Remove oil seal from location.
CAUTION: Do not damage seal location or
running surface on crankshaft.
Refit
4. Ensure both seal location and running surface
on crankshaft are clean.
5. Ensure mating faces of flywheel and crankshaft
are clean.
6. Lubricate seal guide LRT-12-095 with clean
engine oil. Position over crankshaft boss.
7. Lubricate oil seal lip.
8. Position seal squarely. Remove guide.
9. Drift seal into location using LRT-12-091.
10. Fit drive plate. See ENGINE 4.0 V8, Repair,
Drive Plate
12
ENGINE
2
REPAIR
DRIVE PLATE
Remove
1. Remove gearbox and transfer box assembly.
See AUTOMATIC GEARBOX, Repair,
gearbox and transfer box assembly
2. Remove 4 clamp ring bolts. Collect clamp ring.
3. Remove flexible drive plate/starter ring gear
assembly from hub aligner.
4. Remove 6 screws from hub aligner. Remove hub
aligner from crankshaft. Collect shim.
5. Check drive plate for distortion or cracks. Check
starter ring gear for chipped or broken teeth. If
either component shows signs of damage, fit a
new assembly.
Refit
6. Ensure all mating surfaces are clean.
7. Fit shim and hub aligner to crankshaft.
8. Fit hub aligner screws and tighten to 85 Nm, 63
lbf ft.
9. Fit drive plate and clamp ring.
10. Fit clamp ring bolts and tighten to 45 Nm, 33 lbf
ft.
NOTE: It is only necessary to reshim the
drive plate when a new crankshaft or hub
aligner is fitted.
11. Fit gearbox and transfer box assembly. See
AUTOMATIC GEARBOX, Repair, gearbox
and transfer box assembly
4.0 V8
3
REPAIR
ROCKER SHAFT RENEW
1. Remove RH or LH rocker covers. See ENGINE
4.0 V8, Repair, rocker cover - right hand or.
See ENGINE 4.0 V8, Repair, rocker cover -
left hand
2. Loosen four rocker shaft fixings.
3. Remove rocker shaft assembly.
NOTE: Each rocker shaft is notched at
ONE end. Notch must be uppermost and
towards front of engine on right hand side,
towards rear on left hand side.
4. Clean rocker pedestal locations on cylinder
head.
5. Fit rocker shaft assembly, locating push rods to
rockers.
6. Tighten rocker shaft fixings to 38 Nm, 28 lbf ft.
7. Fit rocker covers.
8. Fit RH or LH rocker covers. See ENGINE 4.0
V8, Repair, rocker cover - right hand or See
ENGINE 4.0 V8, Repair, rocker cover - left
hand
OIL SUMP
Remove
1. Drain engine oil See SECTION 10,
Maintenance, Under vehicle maintenance
2. Fit and tighten drain plug to 40 Nm, 30 lbf ft.
3. Remove bolt securing dipstick tube to rocker
cover.
4. Working from the centre outwards, progressively
loosen and remove 3 screws and 14 bolts
securing sump. Remove sump.
5. Remove all traces of sealant from mating
surfaces of sump, cylinder block and timing
cover, using a suitable solvent or plastic scraper.
6. Degrease mating surfaces of sump, cylinder
block and front cover.
Refit
7. Apply RTV Hylosil White sealant to mating
surface of sump.
8. Position sump, tighten bolts finger tight.
9. Tighten nuts and bolts progressively in
sequence shown to 23 Nm, 17 lbf ft.
10. Fit bolt securing dipstick tube to rocker cover.
12
ENGINE
4
REPAIR
ROCKER COVER GASKET - LEFT HAND
Remove
2. Remove plenum chamber. See FUEL SYSTEM,
Repair, plenum chamber
3. Remove screw securing dipstick tube to rocker
cover.
4. Release 4 spark plug leads from guide clips and
disconnect leads from spark plugs.
5. Remove 4 bolts securing rocker cover to cylinder
head.
6. Remove rocker cover.
7. Remove and discard rocker cover gasket.
Refit
8. Clean mating faces of rocker cover and cylinder
head using Bostick 6001 or equivalent. Allow to
dry.
9. Apply a thin coating of impact adhesive (Bostick
1775 or equivalent) to mating faces of rocker
cover and gasket . Use a brush to ensure an
even film. Allow adhesive to become touch dry.
CAUTION: Gasket fits one way round only.
It must be fitted accurately, first time.
Subsequent movement will destroy
bonding.
10. Place one end of gasket into cover recess with
edge firmly against recess wall, holding
remainder of gasket clear. Work around cover
pressing gasket into place ensuring edge firmly
contacts recess wall.
CAUTION: Allow cover to stand for 30
minutes before fitting.
11. Fit rocker cover to cylinder head, ensuring short
bolts are fitted inboard, tighten bolts to 9 Nm, 7
lbf ft.
12. Connect plug leads and secure to guide clips.
13. Align dipstick tube to rocker cover and tighten
screw.
14. Fit plenum chamber. See FUEL SYSTEM,
Repair, plenum chamber
4.0 V8
5
REPAIR
ROCKER COVER GASKET - RIGHT HAND
Remove
2. Disconnect breather hose from plenum chamber
and remove hose from rocker cover.
3. Position container to collect coolant spillage.
4. Remove bolt securing coolant pipe brackets
together and nut securing bracket to manifold.
5. Loosen clip and disconnect coolant return hose
from manifold.
6. Depressurise fuel system. See FUEL SYSTEM,
Adjustment, fuel system depressurise
7. Position cloth to absorb fuel spillage.
8. Disconnect fuel feed hose union.
CAUTION: Plug the connections.
9. Loosen clip and disconnect fuel return hose.
10. Remove 2 bolts securing engine harness
bracket to manifold.
11. Release 4 spark plug leads from guide clips and
disconnect leads from spark plugs.
12. Remove 4 bolts securing rocker cover to cylinder
head.
13. Remove rocker cover.
14. Remove and discard rocker cover gasket.
12
ENGINE
6
REPAIR
Refit
15. Clean mating faces of rocker cover and cylinder
head using Bostick 6001 or equivalent. Allow to
dry.
16. Apply a thin coating of impact adhesive (Bostick
1775 or equivalent) to mating faces of rocker
cover and gasket. Use a brush to ensure an
even film. Allow adhesive to become touch dry.
NOTE: Gasket only fits one way round. It
must be fitted accurately, first time.
Subsequent movement will destroy
bonding.
17. Place one end of gasket into cover recess with
edge firmly against recess wall, holding
remainder of gasket clear. Work around cover
pressing gasket into place ensuring edge firmly
contacts recess wall.
CAUTION: Allow cover to stand for 30
minutes before fitting.
18. Fit rocker cover to cylinder head ensuring short
bolts are fitted inboard, tighten bolts to 9 Nm.
19. Connect plug leads and secure to guide clips.
20. Position harness bracket to inlet manifold and
tighten bolts.
21. Connect fuel feed and return hoses.
22. Connect coolant hose to inlet manifold and
tighten clip.
23. Secure coolant pipe brackets
24. Fit breather hose.
25. Refill cooling system.
ENGINE ASSEMBLY
Remove
1. Position vehicle on 4-post ramp [hoist].
2. Drain engine oil. See SECTION 10,
Maintenance, under vehicle maintenance
3. Remove bonnet. See CHASSIS AND BODY,
Repair, bonnet
4. Remove radiator. See COOLING SYSTEM,
Repair, radiator
5. Loosen 3 PAS pump pulley bolts.
6. Using a 15 mm ring spanner, release auxillary
drive belt tension and release belt from
alternator pulley.
7. Remove drive belt.
8. Disconnect A/C compressor multiplug.
9. Remove 4 bolts securing compressor to
mounting bracket.
10. Collect compressor heat shield.
11. Tie compressor aside with string.
4.0 V8
7
REPAIR
12. Loosen clip screws securing heater return and
feed hoses to pipes and disconnect.
13. Position cloth to collect fuel spillage.
14. Loosen fuel feed hose to rail union, allow fuel to
spill and disconnect union.
15. Loosen clip screw securing fuel return hose to
fuel rail and disconnect hose.
16. Remove cloth.
17. Remove plenum. See FUEL SYSTEM, Repair,
plenum chamber
18. Remove bolt securing 2 breather pipe P clip to
rear of RH cylinder head.
19. Loosen clip screw securing intake hose to MAF
sensor housing and remove hose.
20. Remove nut securing kick-down cable clip to
rear of LH cylinder head.
21. Remove 3 cable ties securing purge pipe to
coolant hose and harness, position pipe aside.
22. Disconnect brake servo pipe from inlet manifold
and position aside.
12
ENGINE
8
REPAIR
23. Remove 3 bolts securing PAS pulley and
remove pulley.
24. Release knock sensor harness clip from PAS
return hose.
25. Remove 3 bolts securing PAS pump and
position aside.
26. Collect engine lifting bracket.
27. Position engine lifting bracket and secure with 3
(3/8 UNC x 1 MAX) bolts.
28. Raise vehicle on ramp.
29. Remove 6 nuts securing exhaust front pipe to
manifolds.
30. Remove front bolt securing RH catalyst heat
shield to chassis.
31. Remove bolt securing starter motor heat shield
to RH engine mounting bracket.
32. Release starter motor heat shield clip from
solenoid.
33. Release exhaust front pipe from manifold studs
and remove and discard gaskets.
34. Remove starter motor heat shield.
4.0 V8
9
REPAIR
35. Remove starter motor solenoid terminal nut.
36. Release 2 battery leads from terminal.
37. Disconnect solenoid Lucar.
38. Disconnect multiplug from RH Knock sensor.
39. Remove 2 cable ties securing engine harness to
RH engine mounting bracket.
40. Disconnect multiplug from LH knock sensor.
41. Remove cable tie securing engine harness to LH
engine mounting bracket.
42. Remove screw securing crankshaft position
sensor heat shield and remove heat shield.
43. Disconnect multiplug from crankshaft position
sensor.
44. Remove bolt securing gearbox cooler pipes to
engine sump bracket.
45. Remove 7 bolts securing bell housing closing
plate and remove plate.
46. Remove 3 bolts securing bell housing access
12
ENGINE
10
REPAIR
47. Mark relationship between converter and drive
plate.
48. Rotate crankshaft to access drive plate to
converter retaining bolts.
49. Remove 4 bolts securing drive plate to
converter.
50. Fit suitable piece of wood through bell housing
access hole to retain converter.
51. Remove 2 bell housing lower retaining bolts.
52. Remove nut securing RH engine mounting to
chassis bracket.
53. Remove nut securing LH engine mounting to
chassis bracket.
54. Lower vehicle.
55. Loosen clip screw and disconnect radiator
bottom hose from heater pipe.
56. Disconnect multiplug from camshaft position
sensor.
57. Disconnect Lucar from oil pressure switch.
58. Release harness from front of engine.
4.0 V8
11
REPAIR
59. Remove 2 alternator terminal nuts and
disconnect Lucar.
60. Remove screw securing heater pipe to bracket.
61. Loosen clip screw and remove heater hose/pipe
assembly from inlet manifold.
62. Remove 2 screws securing engine harness to
RH side of inlet manifold.
63. Disconnect 4 RH injector multiplugs.
64. Disconnect RH rocker cover breather pipe from
ram housing.
65. Release RH bank HT leads from clips and
disconnect from spark plugs.
66. Remove 2 screws securing engine harness to
LH side of inlet manifold.
67. Disconnect multiplug from ECT sensor.
68. Disconnect multiplug from fuel temperature
sensor.
69. Disconnect temperature sensor thermistor.
70. Disconnect 4 LH injector multiplugs.
71. Release ignition coil multiplug from mounting
bracket and disconnect multiplug.
72. Position engine harness aside.
12
ENGINE
12
REPAIR
73. Fit engine lifting tool LRT-12-514 to hoist.
74. Lower hoist and connect lifting chains to engine
brackets.
75. Raise hoist until lifting chains become taught and
use a jact to support gearbox.
76. Remove 6 bell housing to engine bolts.
77. With assistance, raise engine on hoist from
engine compartment.
CAUTION: During the engine removal
procedure ensure that the engine does not
damage any surrounding components.
78. Move engine clear of vehicle and lower onto
work bench.
79. Disconnect lifting chains from engine.
80. Raise hoist and position aside.
Refit
81. Clean engine and gearbox mating faces.
82. Clean dowel and dowel holes.
83. Position hoist above engine.
84. Connect lifting chains to engine.
85. Raise engine from work bench and position
above engine compartment.
86. Position jack beneath gearbox fluid pan and
raise transmission to ease alignment of bell
housing to engine.
CAUTION: Use a block of wood or hard
rubber pad to protect fluid pan.
87. With assistance, lower engine into engine
compartment.
CAUTION: During the engine fitment
procedure ensure that the engine does not
damage any surrounding components.
88. With assistance, align engine to bell housing
dowels.
89. Fit bolts securing bell housing to engine and
tighten to 46 Nm, 34 lbf ft.
NOTE: Align harness brackets to 2
uppermost bell housing retaining bolts.
90. Remove jack supporting gearbox fluid pan.
91. Lower engine hoist ensuring mountings are
aligned with chassis brackets.
92. Disconnect lifting chains from engine eyes.
93. Remove lifting tool LRT-12-514from hoist.
94. Remove hoist from above vehicle.
95. Position engine harness around engine.
96. Connect ignition coil multiplug and secure to
bracket.
97. Connect LH injector multiplugs.
98. Connect gauge temperature thermistor.
99. Connect multiplug to fuel temperature sensor.
100. Connect multiplug to ECT sensor.
101. Connect RH bank HT leads to spark plugs and
secure to guides.
102. Connect RH rocker cover breather pipe to ram
housing.
103. Connect RH injector multiplugs.
104. Align engine harness to RH side of inlet manifold
and secure with screws.
105. Fit heater hose/pipe assembly to inlet manifold
and secure with clip.
106. Align heater pipe to bracket and secure with
screw.
107. Position alternator terminal leads and secure.
108. Route harness down front of engine.
109. Connect Lucar to oil pressure switch.
110. Connect multiplug to camshaft position sensor.
111. Connect radiator bottom hose to heater pipe and
secure with clip.
112. Raise vehicle.
4.0 V8
13
REPAIR
113. Fit nut securing LH engine mounting rubber to
chassis mounting and tighten to 30 Nm, 22 lbf
ft.
114. Fit nut securing RH engine mounting rubber to
chassis mounting and tighten to 30 Nm, 22 lbf
ft.
115. Fit bell housing to engine bolts and tighten to 46
Nm, 34 lbf ft .
116. Remove piece of wood from bell housing access
hole.
117. Align converter to drive plate.
118. Fit bolts securing converter to drive plate and
NOTE: Rotate crankshaft during the above
procedure.
119. Fit bell housing access plate and secure with
bolts tightened to 9 Nm, 7 lbf ft.
120. Clean bell housing cover plate and mating face.
121. Fit plate and secure with bolts tightened to 9
Nm, 7 lbf ft.
122. Connect multiplug to crankshaft position sensor.
123. Fit crankshaft position sensor heat shield and
secure with screw.
124. Position engine harness to LH engine mounting
bracket and secure with cable tie.
125. Connect multiplug to LH knock sensor.
126. Position engine harness to RH engine mounting
bracket and secure with cable ties.
127. Connect multiplug to RH knock sensor.
128. Connect Lucar to starter motor solenoid.
129. Position battery leads to starter motor solenoid
terminal and secure with nut.
130. Position starter motor heat shield.
131. Clean exhaust manifold to front pipe mating
faces.
132. Fit NEW front pipe to manifold gaskets.
133. Connect front pipe to manifold studs and secure
with nuts.
134. Secure starter motor heat shield clip to solenoid.
135. Align starter motor heat shield to RH engine
mounting bracket and secure with bolt.
136. Align RH catalyst heat shield to chassis and
secure with bolt.
137. Lower vehicle.
138. Remove 3 bolts securing engine front lifting
bracket, retain bracket but discard bolts.
139. Position engine lifting bracket to PAS pump,
align to cylinder head and secure with bolts
tightened to 35 Nm, 25 lbf ft.
140. Secure knock sensor harness clip to PAS return
hose.
141. Fit PAS pulley to pump, fit bolts but do not
tighten.
142. Position brake servo pipe and connect to inlet
manifold.
143. Position purge pipe and secure to coolant hose
and harness with cable ties.
144. Fit intake hose to MAF sensor housing and
secure with clip.
145. Position breather pipe P clip to RH cylinder
head and secure with bolt.
146. Fit plenum. See FUEL SYSTEM, Repair,
plenum chamber; Refit
147. Remove plugs from fuel return and feed hose
connections.
148. Clean fuel feed pipe connections.
149. Connect feed hose to fuel rail and tighten union.
150. Connect fuel return hose to fuel rail and secure
with clip.
151. Connect heater feed and return hoses to pipes
and secure with clips.
152. Release A/C compressor and position to
mounting bracket.
153. Position heat shield to compressor fixing, fit bolts
and tighten to 25 Nm, 18 lbf ft.
154. Connect compressor multiplug.
155. Clean drive belt and pulley grooves.
156. Using a 15 mm spanner, rotate tensioner
clockwise, fit belt to pulleys and release
tensioner.
157. Tighten PAS pump pulley bolts to 10 Nm, 7 lbf
ft.
158. Fit radiator. See COOLING SYSTEM, Repair,
radiator
159. Fit bonnet. See CHASSIS AND BODY, Repair,
bonnet
160. Refill engine oil. See SECTION 10,
161. Adjust kick-down cable. See AUTOMATIC
GEARBOX, Adjustment, kickdown cable
adjustment
4.0 V8
1
TORQUE VALUES
Engine V8i Nm lbf ft
Crankshaft pully bolt 270 ......................................................... 200
Camshaft gear bolt 58 ........................................................... 43
Timing cover / coolant pump bolts*** 22 ............................... 16
Rocker cover to cylinder head 9 .......................................... 7
Rocker shaft bracket to cylinder head 38 .............................. 28
Spark plug 15 ........................................................................ 11
Cylinder head bolts:*
Stage 1: 20 ................................................................... 15
Stage 2: then 90 ................................................................... then 90
Stage 3: further 90 ................................................................... further 90
Generator / steering pump bracket to cylinder head 30 ........ 22
Lifting bracket to cylinder heads 40 ....................................... 30
Power steering hose unions:
14 mm 15 ..................................................................... 11
16 mm 20 ..................................................................... 15
Power steering pump heat shield 25 ..................................... 18
Drive belt tensioner 50 .......................................................... 39
Drive plate to converter 40 .................................................... 30
Drive plate to crankshaft 45 .................................................. 33
Drive plate hub aligner to crankshaft socket head screws 85 65
Bell housing bolts 40 ............................................................. 30
Access plate 9 ..................................................................... 7
Bell housing cover plate 9 ................................................... 7
Main bearing cap rear bolts:
Stage 1: 13 ................................................................... 10
Stage 2: 72 ................................................................... 53
Oil sump drain plug 40 .......................................................... 30
Oil sump to cylinder block 23 ................................................ 17
Starter motor bolts 45 ............................................................ 33
Starter motor shield 9 .......................................................... 7
Oil cooler pipe unions to transmission 30 ............................. 22
Tie bar to transmission 45 ..................................................... 33
Gearbox breather pipe bracket 9 ........................................ 7
Engine harness bracket 9 ................................................... 7
Engine mountings to engine and chassis 55 ......................... 40
Engine mounting rubbers to brackets 30 .............................. 22
Compressor heat shield 25 ................................................... 18
* Lightly oil threads prior to assembly
** Apply Loctite 222 to threads before assembly
*** Apply Loctite 577 to threads before assembly
12
ENGINE
2
NOTE: The following torque values are for screws and bolts not specified in the previous table.
METRIC Nm lbf ft
M5 6 ........................................................................... 5
M6 9 ........................................................................... 7
M8 25 ........................................................................... 18
M10 45 ......................................................................... 33
M12 90 ......................................................................... 65
M14 105 ......................................................................... 75
M16 180 ......................................................................... 130
UNC / UNF
1/4 9 ........................................................................... 7
5/16 25 ......................................................................... 18
3/8 40 ........................................................................... 30
7/16 80 ......................................................................... 60
1/2 90 ........................................................................... 65
5/8 135 ........................................................................... 100
EMISSION CONTROL
1
DESCRIPTION AND OPERATION
EMISSION CONTROL
Three systems are used to control the vehicle
atmospheric emissions, these are:
- Engine crankcase fume emissions.
- Fuel tank Evaporative emissions
- Engine exhaust gas emissions.
Crankcase ventilation system
The crankcase ventilation system, which is an integral
part of the air supply to the engine combustion
chambers, is often overlooked when diagnosing
problems associated with engine performance. A
blocked ventilation pipe or excessive air leak into the
inlet system through a damaged pipe or leaking
gasket can effect the mixture, performance and
economy of the engine.
The purpose of the crankcase ventilation system is to
ensure that any noxious gas generated in the engine
crankcase is rendered harmless by burning in the
combustion chambers as follows:
Oil laden noxious gas in the engine crankcase is
drawn through an oil separator located in the RH
cylinder head rocker cover, where the oil is separated
and returned to the sump. The gas flows through a
restrictor and via a hose into the inlet plenum chamber
where it is drawn into the combustion chambers and
burned. The volume of fresh air which is drawn from
the atmospheric side of the throttle butterfly, via a
hose into the LH rocker cover to mix with the gas,
depends on the position of the throttle and the engine
speed.
As the throttle opening increases, manifold depression
increases, and at a given point, the crankcase gases
are drawn into the throttle housing. This reversal helps
to prevent excessive crankcase pressure or
depression developing.
17
EMISSION CONTROL
2
EXHAUST SYSTEM
1. Manifold to front pipe connection.
2. Front oxygen sensor.
3. Front silencer support bracket.
4. Rear oxygen sensor.
5. Front pipe to silencer joint.
6. Silencer rear support bracket.
7. Rear silencer support bracket.
EMISSION CONTROL
3
Exhaust emission control.
The multiport Sequential Fuel injection (SFi) system
provides accurately metered quantities of fuel to the
combustion chambers to ensure the most efficient air
to fuel ratio under all conditions of operation. A further
improvement to combustion is made by measuring the
oxygen content of the exhaust gases to enable the
quantity of fuel injected to be varied, according to
conditions, to correct any unsatisfactory composition
of the exhaust.
The main components of the exhaust emission
system are two catalytic converters which are an
integral part of the front exhaust pipe assembly. The
catalytic converters are included in the system to
reduce the emission, to atmosphere, of carbon
monoxide, oxides of nitrogen, and hydrocarbons. The
active constituents of the converters are platinum and
rhodium. The correct functioning of the converters is
dependent upon close control of the oxygen
concentration in the exhaust gas entering the catalyst.
The oxygen content of the exhaust gas is signalled to
the Engine Control Module (ECM) by Heated Oxygen
Sensors (HO2S) located in the exhaust front pipes
each side of the catalytic converters. The ECM can
then make an appropriate adjustment to the fuel
supply to correct the composition of the exhaust
gases.
CAUTION: Unleaded fuel only must be
used on vehicles fitted with catalytic
converters. As a reminder a label to
indicate this is adhered to the inside of the fuel
filler flap. As a further safeguard, the filler neck is
designed to accommodate only unleaded fuel
pump nozzles.
17
EMISSION CONTROL
4
EVAPORATIVE EMISSION CONTROL SYSTEM
The system is designed to prevent harmful fuel vapour
from escaping to the atmosphere. The system
consists of a vapour separator tank, connected to the
fuel tank and located between the body inner and
outer panels on the right hand side of the vehicle near
the rear wheel arch. An Evaporative Emissions
(EVAP) canister, containing activated charcoal, is
positioned in the engine compartment attached to the
front right valance. The two components are
connected by a pipe running the length of the chassis.
A Pressure relief to atmosphere.
B From fuel tank to separator.
C To evaporative emmissions canister.
D Pressure relief valve.
E Pressure relief valve.
F Shut-off valve.
G "Speed Fit" connectors.
A pressure relief valve is fitted in the hose which is
open to atmosphere. This valve acts as a safety valve
should a build-up of pressure occur in the system, for
example if a hose became blocked or kinked. The
volume of vapour emitted, in such an instance, would
be limited.
A pressure relief valve is also fitted in the hose
connected to the adsorption canister and releases
vapor to the canister when the pressure in the
separator reaches between 5 and 7 Kpa, 0.7 and 1.0
lbf/in
2
.
In the top of the separator a shut-off valve is
incorporated in the vapour exit port to prevent the
possible presence of any liquid fuel being transmitted
to the EVAP canister should the vehicle roll over.
The EVAP canister, which is connected by a hose to
the plenum chamber, absorbs and stores the fuel
vapour from the fuel tank while the engine is not
running. When the engine is started, the vapour is
purged from the canister by air drawn through an
orifice in the base of the canister and by the influence
of vacuum at the top. The vapour drawn into the
plenum chamber through a solenoid operated purge
valve is finally burnt in the combustion chambers.
The purge valve, which is attached to the evap
canister support bracket, is controlled by the Engine
Control Module ECM which determines the optimum
time at which purging should take place. This will
normally be at engine speeds above idle and when
the vehicle is in motion. A signal from the ECM to the
purge valve operates the solenoid and opens the
valve to purge the canister of fuel vapour.
EMISSION CONTROL
5
1. Vapour separator and pipes
2. Non-return valve to atmosphere
3. Pipe from fuel tank
4. Pipe to EVAP canister
5. EVAP canister and purge valve
6. Fuel tank
EMISSION CONTROL
1
FAULT DIAGNOSIS
TESTING EVAPORATIVE EMISSION CONTROL
Equipment required.
Nitrogen cylinder (compressed air may be used to
pressure the system when there has NEVER been
fuel present in the fuel or evaporative control
systems).
The following pressure test procedure is intended to
provide a method for ensuring that the system does
not leak excessively and will effectively control
evaporative emissions.
Water manometer (0 - 30" H2O or more).
Pipework and a "T" piece.
Method.
1. Ensure that there is at least two gallons of fuel in
the petrol tank unless there has never been any
fuel in the system.
2. Disconnect, at the EVAP canister, the pipe to the
vapour separator.
3. Connect this pipe to the nitrogen cylinder and
the water manometer using the "T" piece.
4. Pressurize the system to between 26.5 and 27.5
inches of water, allow the reading to stabilize,
then turn off the nitrogen supply.
5. Measure the pressure drop within a period of 2
minutes 30 seconds. If the drop is greater than
2.5 inches of water the system has failed the
test. Note that a fully sealed system will show a
slight increase in pressure.
6. Should the system fail the test, maintain the
pressure in the system and apply a soap
solution round all the joints and connections until
bubbles appear to reveal the source of the leak.
7. Repeat the test and if successful, dismantle the
test equipment and reconnect the pipe to the
EVAP canister.
EMISSION CONTROL
1
REPAIR
EVAP CANISTER AND PURGE CONTROL VALVE
Remove
1. Remove 3 clips securing purge pipe to coolant
hose.
2. Depress tags and disconnect purge pipe from
plenum chamber.
3. Remove PAS reservoir clamp bracket bolt.
4. Open clamp and release reservoir from bracket.
5. Remove 2 nuts securing bracket to wing.
6. Release bracket from wing and disconnect
multiplug from purge valve.
7. Release clip and disconnect fuel tank vapour
separator pipe from canister pipe.
8. Move PAS reservoir aside, release and remove
charcoal canister, purge valve and bracket
assembly.
Do not carry out further dismantling if component
is removed for access only.
9. Remove bracket from purge valve.
Refit
10. Fit bracket to purge valve.
11. Position assembly, connect vapour separator
pipe to canister pipe and secure with clip.
12. Locate purge valve bracket and expansion hose
clip to studs and locate assembly to wing.
13. Fit and tighten nuts.
14. Locate PAS reservoir to bracket clip, compress
clip, fit bolt and tighten to 8 Nm, 6 lb ft.
15. Connect purge pipe to plenum chamber.
16. Secure purge pipe to coolant hose with clips.
17
EMISSION CONTROL
2
REPAIR
VAPOUR SEPARATOR
Remove
1. Remove 7 screws securing floor carpet rear
retainer.
2. Release lower section of door sealing rubber on
one side.
3. Remove carpet retainer.
4. Fold floor carpet back on RH side.
5. Release RH side carpet and move aside to
reveal 2 screws securing vapour separator.
6. Remove 2 screws securing vapour separator.
7. Release vapour separator pipe from clip on fuel
pipe.
8. Depress 2 lugs on vapour separator connector
and disconnect pipe.
9. Using tool LRT-19-002 depress collar at green
end of speedfit connector and disconnect pipe.
10. Remove vapour separator.
Refit
11. Position vapour separator and connect pipes.
12. Using assistance, align vapour separator and fit
and tighten screws.
13. Apply adhesive to side carpet and body.
14. Fold down side and floor carpets.
15. Fit carpet retainer and fit and tighten screws.
16. Secure door sealing rubber.
EMISSION CONTROL
3
REPAIR
FRONT PIPE / CATALYTIC CONVERTER
Remove
WARNING: The removal of the exhaust
system must only be carried out when the
engine is cold.
2. Remove oxygen sensors. See FUEL SYSTEM,
Repair, Heated oxygen sensor (ho2s) - front
and See FUEL SYSTEM, Repair, Heated
oxygen sensor (ho2s) - rear
3. Remove 4 bolts securing front anti-roll [sway] bar
mounting brackets.
4. Remove 6 nuts securing front pipe assembly to
exhaust manifolds.
5. Remove 2 nuts securing front pipe assembly to
intermediate pipe.
6. With assistance, release front pipe assembly
from exhaust manifolds.
7. With assistance, release front pipe assembly
from intermediate pipe.
8. With assistance, lower anti-roll [sway] bar and
remove front pipe assembly.
9. Remove and discard flange gaskets.
Refit
10. Clean exhaust flange mating faces.
11. Fit new flange gaskets.
12. With assistance, position front pipe to vehicle.
13. With assistance, locate front pipe on exhaust
manifolds and intermediate pipe.
14. Fit and tighten flange nuts.
15. Reposition front anti-roll [sway] bar and secure
with bolts.
16. Fit heated oxygen sensors. See FUEL
SYSTEM, Repair, Heated oxygen sensor
(ho2s) - front and See FUEL SYSTEM, Repair,
Heated oxygen sensor (ho2s) - rear
17. Lower vehicle.
SFI
1
ENGINE MANAGEMENT SYSTEM COMPONENT
LOCATION
1. Engine Control Module (ECM)
2. Ignition coils
3. Fuel pressure regulator
4. Mass air flow (MAF) sensor
5. Relay module
- Main relay
- Fuel pump relay
6. Engine coolant temperature (ECT) sensor
7. Camshaft position (CMP) sensor
8. Throttle position (TP) sensor
19
FUEL SYSTEM
2
1. EVAP purge valve
2. Inertia switch
3. Engine fuel temperature (EFT) sensor
4. Crankshaft position (CKP) sensor
5. Heated oxygen sensor (HO2S) - 4 off
6. Injectors - 8 off
7. Idle air control valve (IACV)
8. Knock sensors - 2 off
9. Intake air temperature (IAT) sensor
SFI
3
ENGINE MANAGEMENT SYSTEM
Description
The engine management system (EMS) maintains
optimum engine performance over the entire
operating range. The correct amount of fuel is
metered into each cylinder inlet tract and the ignition
timing is adjusted at each spark plug.
The system is controlled by the Engine Control
Module (ECM) which receives data from sensors
located on and around the engine. From this
information it provides the correct fuel requirements
and ignition timing to suit all engine loads and speeds.
The fuel injection system uses a hot wire Mass Air
Flow sensor to calculate the amount of air flowing into
the engine.
The ignition system does not use a distributor. It is a
direct ignition system (DIS), using four double ended
coils. The circuit to each coil is completed by
switching inside the ECM.
The on board diagnostic system detects any faults
which may occur within the EMS. Fault diagnosis
includes failure of all EMS sensors and actuators,
emissions related items, fuel supply and exhaust
systems.
The system incorporates certain default strategies to
enable the vehicle to be driven in case of sensor
failure. This may mean that a fault is not detected by
the driver. The fault is indicated by illumination of the
malfunction indicator light (MIL).
Crankshaft position (CKP) sensor
The crankshaft position sensor is the most important
sensor on the engine. It is located in the left hand side
of the torque convertor housing. The signal it
produces informs the ECM:
- that the engine is turning
- how fast the engine is turning
- at which stage the engine is, in the combustion
cycle.
As there is no default strategy, failure of the
crankshaft sensor will result in the engine failing to
start. The fault is indicated by illumination of the
malfunction indicator light (MIL).
Camshaft position (CMP) sensor
The camshaft position sensor is located in the engine
front cover. It produces four pulses every two
revolutions. The signals are used in two areas,
injector timing corrections for fully sequential fuelling
and active knock control.
If the camshaft sensor fails, default operation is to
continue normal ignition timing. The fuel injectors will
be actuated sequentially, timing the injection with
respect to top dead centre. Injection will either be
correct or one revolution out of synchronisation. The
fault is not easily detected by the driver. Sensor failure
will be indicated by illumination of the malfunction
indicator light (MIL).
Mass air flow (MAF) sensor
The hot wire type mass air flow sensor is mounted
rigidly to the air filter and connected by flexible hose to
the plenum chamber inlet. The sensing element of the
MAF Sensor is a wire which is heated. Air flows
across the heated wire cooling it and thus changing its
resistance. The ECM measures this change in
resistance, and together with intake air temperture
sensor resistance, calculates the amount of air flowing
into the engine.
As there is no default strategy, failure will result in the
engine starting, and dying when it reaches 550
rev/min, when the ECM detects no MAF Sensor
signal. The fault is indicated by illumination of the
malfunction indicator light (MIL) on North American
specification vehicles.
Throttle position (TP) sensor
The throttle position sensor is mounted on the plenum
chamber and connected directly to the throttle shaft.
The sensor is a variable resistor, the signal from
which (0 - 5V) informs the ECM of the actual position
of the throttle disc. As there is no default strategy,
failure of the sensor will result in poor idle and lack of
throttle response. If failure occurs in the closed
position the engine will only reach 1750 rev/min when
the ECM will initiate overrun fuel cut off. The fault is
indicated by illumination of the malfunction indicator
light (MIL).
19
FUEL SYSTEM
4
Engine coolant temperature (ECT) sensor
This sensor consists of a temperature dependant
resistive metal strip. The resistance of the strip varies
considerably with coolant temperature, i.e.
- 28K ohms at 30C, 86F
- 300 ohms at 85C, 185F
- 90 ohms at 130C, 266F
The ECT Sensor signal is vital to engine running, as
the correct fuelling is dependant upon engine
temperature i.e. richer mixture at low temperatures. If
the sensor is disconnected or failure occurs a default
value will be supplied to the system. The initial default
value selected will be based on the value of the air
intake temperature. This will increase to a nominal
warmed up value over an individual time, programmed
for each default value. The fault may not be evident to
the driver, though there may be a hot restart problem.
The fault is indicated by illumination of the malfunction
indicator light (MIL).
Intake air temperature (IAT) sensor
This is another resistive sensor, located in the body of
the air cleaner. The resistance varies with changes in
air temperature. The signal from the IAT Sensor is
used to retard the ignition timing if the air temperature
rises above 55C. If the sensor is disconnected or
failure occurs a default value will be supplied to the
system. The default value selected will represent
normal operating conditions. The fault may not be
evident to the driver, there may be slight power loss in
high ambient temperatures. The fault is indicated by
illumination of the malfunction indicator light (MIL) on
North American specification vehicles.
Engine fuel temperature (EFT) sensor
The EFT sensor is located on the fuel rail. This sensor
measures temperature of the rail rather than the fuel.
The resistance varies with changes in temperature.
The signal is used to increase the injection pulse time
when undergoing hot restarts. When the fuel is hot,
vapourisation occurs in the rail which may result in the
formation of bubbles in the injectors. Increasing the
pulse time helps flush the bubbles away and cools the
fuel rail with fuel from the tank.
An EFT sensor fault may not be evident to the driver,
there may be a hot restart problem. The fault is
light (MIL).
Knock sensors
The knock sensor produces an output voltage in
proportion to mechanical vibration caused by the
engine. A sensor is located in each cylinder bank
between 2/4 and 3/5 cylinders. The ECM calculates if
the engine is knocking by taking camshaft and
crankshaft sensor signals to determine the position of
the engine in the combustion cycle.
The ECM can also work out exactly which cylinder is
knocking and retards the ignition on that particular
cylinder until the knock disappears. It then advances
the ignition to find the optimum ignition timing for that
cylinder.
The ECM can simultaneously adjust the timing of
each cylinder for knock . It is possible that all eight
cylinders could have different advance angles at the
same time. If the camshaft sensor fails, the knock
sensor will continue to work, but as the engine may be
running one revolution out of sychronisation the ECM
may retard the wrong cylinder of the pair e.g. 1
instead of 6. If the knock sensor fails engine knock will
not be detected and corrected. The fault is indicated
by illumination of the malfunction indicator light (MIL).
Rough Road Detection
With the vehicle in motion, the rough road detection
ECU receives signals from a speed sensor mounted
at each wheel. The system checks for differing wheel
speeds and uses this information to determine when
the vehicle is off road, to prevent the ECM logging
false misfires.
SFI
5
Ignition coils
The electronic ignition system uses four double ended
coils. They are mounted on a bracket fitted to the rear
of the engine. The circuit to each coil is completed by
switching within the ECM, allowing each coil to charge
up and fire. Sparks are produced in two cylinders
simultaneously, one on compression stroke, the other
on exhaust stroke. Note that coil 1 feeds cylinders 1
and 6, coil 2 feeds cylinders 5 and 8, coil 3 feeds
cylinders 4 and 7, and coil 4 feeds cylinders 2 and 3.
The resistance of the spark in the compression
cylinder is higher than that in the exhaust cylinder.
Coil failure will result in a lack of ignition, resulting in
misfire in the effected cylinders. The fault is indicated
by illumination of the malfunction indicator light (MIL)
on North American specification vehicles.
Injectors
A multiport Sequential Fuel injection (SFI) system is
used, one injector per cylinder. Each injector consists
of a small solenoid which is activated by the ECM to
allow a metered amount of fuel to pass into the
combustion chamber. Due to the pressure in the fuel
rail and the shape of the injector orifice, the fuel
squirts into the cylinder in a fine spray to aid
combustion. In the unlikely event of total injector
failure or leakage which will cause rich mixture, a
misfire will occur in the affected cylinder. The fault is
light (MIL) on North American specification vehicles.
Idle air control (IAC)
Idle speed is controlled by a stepper motor which
consists of two coils. When energised in the correct
sequence the coils move a plunger which opens and
closes the throttle bypass controlling the quantity of
idle air. The stepper motor controls idle speed by
moving the plunger a set distance called a step. Fully
open is 200 steps and fully closed 0 steps. Failure of
the stepper motor will result in low or high idle speed,
poor idle, engine stall or non start. The fault is
light (MIL) on North American specification vehicles.
Heated oxygen sensor (HO2S)
The oxygen sensors consist of a titanium metal
sensor surrounded by a gas permeable ceramic
coating. Oxygen in the exhaust gas diffuses through
the ceramic coating on the sensor, and reacts with the
titanium wire altering the resistance of the wire. From
this resistance change the ECM calculates the
amount of oxygen in the exhaust gas. The injected
fuel quantity is then adjusted to achieve the correct
air/fuel ratio, thus reducing the emissions of carbon
monoxide (CO), hydrocarbons (HC),and oxides of
nitrogen (NO
x
). Four HO2 sensors are fitted in the
exhaust front pipe, two each side, and positioned in
front and behind each catalyst. The two rear sensors
are used to monitor the operating efficiey of the
catalysts. Note that if the wiring to these sensors is
crossed, the vehicle will start and idle correctly until
the sensors reach operating temperature. Then the
ECM will read the signals from them and send one
bank of cylinders very rich and the other very weak.
The engine will misfire, have a rough idle and emit
black smoke, with possible catalyst damage.
In the event of sensor failure, the system will default to
open loop and fuelling will be calculated using
signals from the remaining ECM inputs.
A fault is indicated by illumination of the malfunction
indicator light (MIL). ECM diagnostics also use HO2
sensors to detect catalyst damage, misfire and fuel
system faults.
19
FUEL SYSTEM
6
Fuel pressure regulator
The fuel pressure regulator is a mechanical device
controlled by manifold depression and is mounted at
the rear of the engine in the fuel rail. The regulator
ensures that fuel rail pressure is maintained at a
constant pressure difference to that in the inlet
manifold, as manifold depression increases the
regulated fuel pressure is reduced in direct proportion.
When pressure exceeds the regulator setting excess
fuel is spill returned to the fuel tank swirl pot which
contains the fuel pick-up strainer.
Failure of the regulator will result in a rich mixture at
idle but normal at full load, or a rich mixture resulting
in engine flooding, or a weak mixture. Although the
fault will not illuminate the MIL, faults caused by the
failure may be indicated.
Relay module
The engine management system employs a relay
module, which houses the main relay and the fuel
pump relay.
Main relay
The main relay supplies the power feed to the ECM
and, the fuel injectors (8 amps) and mass air flow
sensor (4 amps). This relay is controlled by the ECM.
This enables the ECM to remain powered up after
ignition is switched off.
During the ECM power down routine the ECM
records all temperature readings and powers the
stepper motor to the fully open position. Failure of this
relay will result in the ECM not being switched on
resulting in engine not starting due to absence of fuel
and ignition.
Fuel pump relay
The fuel pump relay is fed from the ignition relay and
controlled by the ECM. The relay is activated in
ignition key position 2 to prime the fuel system for a
period of time controlled by the ECM. Failure of this
relay will result in no fuel pressure.
Inertia fuel shut-off switch
The inertia switch isolates the power supply to the fuel
pump in the event of sudden deceleration. The inertia
switch is located in the engine compartment. It is reset
by depressing the central plunger at the top of the
switch.
Engine immobilization
A coded signal is sent from the immobilization unit,
located behind the instrument panel, to the vehicle
ECM. If the coded signal does not match the signal
expected by the ECM, the ECM immobilizes the
starting and fuel circuits.
SFI
1
ADJUSTMENT
ENGINE TUNING
The position of the Idle Air Control (IAC) valve can be
checked using TestBook and adjusted if necessary
through the by-pass screw in the plenum chamber.
The bypass screw is covered by a tamper proof plug
which can be extracted using a self tapping screw.
All vehicles:
1. Ensure air conditioning and all electical loads are
off. Vehicle must be in neutral or park.
2. Carry out tuning or base idle setting procedure
as applicable using TestBook.
FUEL SYSTEM DEPRESSURISE
WARNING: Fuel pressure of up to 2.5 bar
will be present in the system, even if the
engine has not been run for some time.
Always depressurise the system before
disconnecting any components in the fuel feed
line (between fuel pump and pressure regulator).
The spilling of fuel is unavoidable during this
operation. Ensure that all precautions are taken to
NOTE: Fuel pressure can be relieved at
fuel rail feed union or fuel filter unions.
1. Position cloth around relevant union to protect
against fuel spray.
2. Carefully loosen union.
3. Tighten union to correct torque once pressure is
relieved.
FUEL TANK DRAIN
WARNING: Ensure that Fuel Handling
Precautions given in Section 01 -
carrying out following instructions.
CAUTION: Before disconnecting any part
of the fuel system, it is imperative that all
dust, dirt and debris is removed from
around components to prevent ingress of foreign
matter into fuel system.
2. Remove fuel filler cap.
3. Using a fuel bowser with an 18 mm, 0.75 in
outside diameter hose, pass hose into tank
through filler neck.
NOTE: Because the fuel tank filler stub
houses a restrictor, repeated attempts may
be necessary to enter the hose into the
fuel tank. Follow the fuel bowser manufacturers
instructions for safe use of bowser.
4. Siphon fuel from fuel tank.
5. Fit filler cap.
SFI
1
REPAIR
IGNITION COILS - SET
Remove
2. Noting their fitted positions, disconnect 8 h.t.
leads from ignition coils.
3. Move leads aside.
4. Disconnect coil multiplug and release from
mounting bracket.
5. Remove 4 nuts securing coil mounting bracket to
engine.
6. Remove coils and mounting bracket assembly.
Do not carry out further dismantling if
component is removed for access only.
7. Remove terminal cover and note lead positions.
8. Remove 2 nuts securing leads to coil terminals.
9. Remove leads from terminals.
10. Remove 3 Torx screws securing ignition coil to
mounting bracket.
11. Remove ignition coil.
12. Fit ignition coil to mounting bracket and secure
with screws.
13. Fit leads to terminals and secure with nuts.
Refit
14. Position coils and mounting bracket assembly to
engine.
15. Fit and tighten nuts securing mounting bracket to
engine to 8 Nm, 6 lbf ft.
16. Connect coil multiplug and secure to mounting
bracket.
17. Connect h.t. leads to ignition coils.
19
FUEL SYSTEM
2
REPAIR
ELECTRONIC CONTROL MODULE (ECM)
Remove
1. Remove 2 screws securing ECM cover.
2. Remove cover.
3. Disconnect 3 multiplugs from ECM.
4. Remove 2 screws securing ECM.
5. Release ECM from 2 lower retainers.
6. Remove ECM.
Refit
7. Position ECM and secure to lower retainers.
8. Fit and tighten screws securing ECM.
9. Connect multiplugs.
10. Fit cover and secure with screws.
INTAKE AIR TEMPERATURE (IAT) SENSOR
Remove
1. Disconnect multiplug from IAT sensor.
2. Remove IAT sensor from air filter housing.
Refit
3. Clean sensor and mating face on filter housing.
4. Fit sensor and tighten to 8 Nm, 6 lbf ft.
5. Connect multiplug.
SFI
3
REPAIR
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR
Remove
2. Depress spring clip and disconnect ECT sensor
multiplug.
3. Position cloth around ECT sensor to absorb
coolant spillage.
4. Remove ECT sensor.
5. Remove sealing washer and discard.
Refit
6. Clean sealing washer, sensor threads and
sensor location.
7. Coat sensor threads with Loctite 577 and fit new
sealing washer.
8. Fit ECT sensor and tighten to 20 Nm, 15 lbf ft.
9. Connect multiplug to ECT sensor.
10. Top up cooling system.
11. Run engine to normal operating temperature.
Check for leaks around ECT sensor.
CRANKSHAFT POSITION (CKP) SENSOR
Remove
2. Raise vehicle on ramp [hoist].
3. Remove 2 bolts securing sensor shield to engine
backplate.
4. Release sensor shield.
5. Remove sensor shield.
6. Disconnect multiplug and remove sensor.
7. Remove spacer from sensor.
CAUTION: All vehicles have a spacer fitted
to the sensor. Ensure spacer is correctly
refitted.
Refit
8. Clean mating faces of sensor and engine
backplate.
9. Fit spacer to sensor.
10. Position sensor and connect multiplug.
11. Position shield to sensor and align to engine
backplate.
12. Fit bolts and tighten to 6 Nm, 4 lbf ft.
13. Lower vehicle.
19
FUEL SYSTEM
4
REPAIR
CAMSHAFT POSITION (CMP) SENSOR
Remove
2. Release sensor multiplug from clip and
disconnect multiplug.
3. Remove bolt securing sensor to front cover.
4. Remove sensor.
5. Remove and discard O ring.
Refit
6. Clean sensor and mating face on front cover.
7. Lubricate and fit O ring to sensor.
8. Fit sensor, fit bolt and tighten to 8 Nm, 6lbf ft.
9. Connect sensor multiplug and secure to bracket.
KNOCK SENSOR - LH
CAUTION: Due to the sensitivity of the
sensor, do not apply tape or sealant to
sensor threads.
Remove
2. Depress spring clip and disconnect multiplug
from LH knock sensor.
3. Remove sensor from engine.
Refit
4. Clean mating faces of sensor and engine.
CAUTION: Failure to tighten sensor to
correct torque will result in malfunction or
sensor damage.
6. Connect multiplug to sensor.
7. Lower vehicle.
SFI
5
REPAIR
KNOCK SENSOR - RH
CAUTION: Due to the sensitivity of the
sensor, do not apply tape or sealant to
sensor threads.
Remove
to engine RH mounting.
3. Release heat shield clip from starter solenoid.
4. Move heat shield aside to gain access to knock
sensor.
5. Depress spring clip and disconnect sensor
multiplug.
6. Remove sensor.
Refit
7. Clean sensor and mating face.
CAUTION: Failure to tighten sensor to
correct torque will result in malfunction or
sensor damage.
9. Connect multiplug to sensor.
10. Manoeuvre heat shield into position.
11. Secure heat shield clip to solenoid.
12. Align heat shield to mounting and secure with
bolt.
13. Lower vehicle.
19
FUEL SYSTEM
6
REPAIR
INERTIA FUEL SHUT OFF SWITCH
Remove
2. Disconnect multiplug from inertia fuel shut off
switch.
3. Remove 2 screws securing shut off switch to
mounting bracket.
4. Remove shut off switch.
Refit
5. Position fuel shut off switch to mounting bracket
6. Connect multiplug to inertia switch.
RELAY MODULE
Remove
1. Remove 2 screws securing ECM cover.
2. Remove cover.
3. Remove 2 screws securing ECM.
4. Release ECM from 2 lower retainers and move
aside for access to relay module.
5. Release relay module from bracket.
6. Disconnect 2 multiplugs from module.
7. Remove relay module.
SFI
7
REPAIR
Refit
8. Position relay module
9. Connect multiplugs and secure module to
bracket.
10. Position ECM and secure to lower retainers.
11. Fit and tighten screws securing ECM.
12. Fit cover and tighten screws.
AIR CLEANER
Remove
1. Loosen clip securing intake hose to MAF sensor
and disconnect hose.
2. Disconnect multiplug from IAT sensor.
3. Release 2 toggle clips and release MAF sensor
from air cleaner.
4. Remove O ring and carefully place sensor
aside.
5. Remove 3 nuts securing air cleaner to mounting
rubbers.
6. Remove air cleaner assembly.
7. Remove IAT sensor.
Refit
8. Clean threads of IAT sensor and fit sensor to air
cleaner.
9. Position air cleaner to mountings and fit and
tighten nuts.
10. Clean MAF sensor and mating face.
11. Fit NEW O ring, fit sensor and secure toggle
clips.
12. Connect multiplug to IAT sensor.
13. Connect air intake hose and tighten clip.
19
FUEL SYSTEM
8
REPAIR
AIR CLEANER ELEMENT
Remove
1. Release 3 toggle clips and remove inlet tube.
2. Remove nut and end plate retaining air cleaner
element.
3. Remove air cleaner element and discard.
Refit
1. Clean inlet tube and inside of air cleaner.
2. Squeeze open dump valve fitted at base of air
cleaner and check that rubber is flexible and in
good condition. Replace if necessary.
3. Fit new air cleaner element.
4. Fit retaining plate and fit and tighten nut.
5. Fit intake tube and secure toggle clips.
THROTTLE CABLE
Remove
1. Remove split pin and clevis pin securing cable to
throttle lever.
2. Release cable adjusting nut from abutment
bracket.
3. Remove split pin and clevis pin securing cable to
throttle pedal.
4. Release cable from bulkhead and remove cable.
SFI
9
REPAIR
Refit
5. Clean area around cable hole in bulkhead.
6. Position cable and secure to bulkhead.
7. Clean and lubricate clevis pin.
8. Align inner cable to throttle pedal, fit clevis pin
and secure with NEW split pin.
9. Secure outer cable to abutment bracket.
10. Clean and lubricate clevis pin.
11. Adjust outer cable and align inner cable yoke to
throttle lever.
12. Fit clevis pin and secure with new split pin.
13. Adjust outer cable to give 1.6 mm, 0.06 inch of
free play in inner cable.
14. Check throttle operation.
FUEL TEMPERATURE SENSOR
Remove
NOTE: Because fuel leakage will not occur
when sensor is removed, it is not
necessary to depressurise the fuel system
for this operation.
1. Release and move brake servo vacuum pipe
aside for access to fuel temperature sensor.
2. Disconnect multiplug from fuel temperature
sensor.
3. Remove sensor.
Refit
4. Clean threads of sensor and mating face on fuel
rail,
5. Fit sensor and tighten to 17Nm, 13 lbf ft.
6. Connect multiplug and vacuum pipe.
19
FUEL SYSTEM
10
REPAIR
HEATED OXYGEN SENSOR (HO2S) - FRONT
Remove
CAUTION: The sensor must only be
removed when the exhaust pipe is cold.
1. Position vehicle on ramp [hoist].
2. Remove clip securing oxygen sensor lead to
harness.
3. Release sensor multiplug from bracket behind
cylinder head.
4. Disconnect multiplug.
5. Raise ramp [hoist].
6. Remove sensor using tool LRT-12-047.
CAUTION: Although robust within the
vehicle enviroment, HO2 sensors are
easily damaged by dropping, excessive
heat and contamination. Care must be exercised
when working on the exhaust system not to
damage the sensor housing or tip.
7. Remove and discard sealing washer.
Refit
8. Clean sensor mating face on exhaust pipe.
NOTE: The new sensor thread is
pre-treated with an anti-seize compound. If
refitting old sensor, fit NEW sealing
washer and apply anti-seize compound to threads.
CAUTION: Do not allow anti-seize
compound to come into contact with the
sensor nose or enter the exhaust system.
9. Fit sealing washer to sensor and fit sensor.
Tighten sensor to 20 Nm, 15 lbf ft.
10. Lower ramp [hoist].
11. Connect multiplug and secure to bracket.
12. Secure lead to harness with clip.
SFI
11
REPAIR
HEATED OXYGEN SENSOR (HO2S) - REAR
Remove
CAUTION: The sensor must only be
removed when the exhaust pipe is cold.
2. Release sensor multiplug from bracket.
3. Disconnect multiplug.
5. Remove sensor using tool LRT-12-047.
6. Remove and discard sealing washer.
Refit
7. Clean sensor mating face on exhaust pipe.
NOTE: The new sensor thread is
pre-treated with an anti-seize compound. If
refitting old sensor, fit NEW sealing
washer and apply anti-seize compound to threads.
CAUTION: Do not allow anti-seize
compound to come into contact with the
sensor nose or enter the exhaust system.
8. Fit sealing washer to sensor and fit sensor.
Tighten sensor to 20 Nm, 15 lbf ft.
9. Connect multiplug and secure to bracket.
19
FUEL SYSTEM
12
REPAIR
MASS AIR FLOW (MAF) SENSOR
Remove
1. Loosen clip securing air intake hose to MAF
sensor and disconnect.
2. Disconnect multiplug from sensor.
3. Release 2 clips securing sensor to air cleaner.
4. Remove sensor, collect and discard O ring.
Refit
5. Clean sensor and mating faces.
6. Fit NEW O ring to sensor.
7. Fit sensor to air cleaner and secure clips.
9. Connect air intake hose to sensor and tighten
clip.
PLENUM CHAMBER
Remove
2. Loosen clip securing air intake hose to plenum
chamber.
3. Disconnect air intake hose.
4. Remove split pin from throttle cable clevis pin.
5. Remove clevis pin.
6. Release and remove kick down cable clevis pin.
7. Release throttle cable from abutment bracket.
8. Remove front locknut from kick down cable.
9. Release cable from bracket.
SFI
13
REPAIR
10. Disconnect purge hose from plenum chamber.
11. Disconnect breather hose from plenum chamber.
12. Depress spring clip and disconnect TP sensor
multiplug.
13. Disconnect multiplug from IACV.
14. Remove 6 bolts securing plenum chamber to
inlet manifold.
15. Release plenum chamber from inlet manifold.
16. Fit hose clamp to water jacket coolant hoses.
17. Tighten clamp.
18. Position cloth to absorb coolant spillage.
19. Loosen clips securing coolant hoses to plenum
chamber.
20. Release hoses from plenum chamber.
21. Remove plenum chamber.
22. Place cloth over ram housing.
23. Remove 4 bolts securing water jacket to plenum
chamber.
24. Remove water jacket from plenum chamber.
25. Remove gasket from water jacket.
26. Move throttle linkage aside to gain access to
mounting bolts.
27. Remove 3 bolts securing throttle linkage to
plenum chamber.
28. Remove throttle linkage and collect spring.
29. Remove 2 screws securing TP sensor to plenum
chamber.
30. Remove TP sensor and collect clamping plate.
31. Remove 2 bolts securing IACV to plenum
chamber.
32. Remove IACV and collect gasket.
19
FUEL SYSTEM
14
REPAIR
Refit
33. Position throttle linkage and spring to plenum
chamber.
34. Fit spring to linkage.
35. Hold throttle open to gain access to mounting
bolts.
36. Fit and tighten mounting bolts to 8 Nm, 6 lbf ft.
37. Clean mating faces of TP sensor and plenum
chamber.
38. Fit TP sensor and engage spindle.
39. Fit clamping plate and tighten bolts to 2 Nm, 1.5
lbf ft.
40. Clean mating faces of IACV and plenum
chamber.
41. Fit gasket to IACV.
42. Fit IACV to plenum chamber and tighten bolts to
2 Nm, 1.5 lbf ft.
43. Clean mating faces of water jacket and plenum
chamber.
44. Position gasket to plenum chamber.
45. Fit water jacket to plenum chamber and tighten
bolts to 13 Nm, 10 lbf ft.
46. Remove cloth from ram housing.
47. Clean plenum and inlet manifold mating faces.
48. Position plenum chamber.
49. Connect coolant hoses to plenum chamber.
50. Tighten hose clips.
51. Loosen and remove hose clamp.
52. Remove cloth.
53. Apply a thin, uniform coating of Loctite 577
sealant to sealing face of plenum chamber.
54. Fit plenum chamber and tighten bolts to 24 Nm,
18 lbf ft.
55. Connect multiplug to TP sensor.
56. Connect multiplug to IACV.
57. Connect breather hose to plenum chamber.
58. Connect purge hose to plenum chamber.
59. Fit kick down cable to abutment bracket, fit
locknut and adust cable. See AUTOMATIC
GEARBOX, Adjustment, Kickdown cable
adjustment
60. Connect throttle cable to abutment bracket.
61. Align throttle cable to lever, fit clevis pin and
secure with new split pin.
62. Align kick down cable to lever.
63. Fit and secure clevis pin.
64. Connect air intake hose and secure with clip.
66. Top up cooling system.
THROTTLE POSITION (TP) SENSOR
Remove
1. Disconnect multiplug from TP sensor.
2. Remove 2 screws securing TP sensor and
collect clamp plate.
3. Remove TP sensor.
Remove
4. Clean TP sensor and mating face.
5. Fit sensor ensuring drive engages with throttle
spindle.
6. Position clamp plate, fit screws and tighten to 2
Nm, 1.5 lbf ft.
SFI
15
REPAIR
IDLE AIR CONTROL VALVE (IACV)
Remove
2. Disconnect multiplug from IACV.
3. Remove 2 bolts securing IACV to plenum
chamber.
4. Remove IACV.
5. Remove gasket and discard.
Refit
6. Clean mating faces of IACV and plenum
chamber.
7. Clean plunger on IACV and plunger seat on
plenum chamber.
8. Using a new gasket, fit IACV to plenum
chamber.
9. Fit and tighten bolts securing IACV to plenum
chamber to 2 Nm, 1.5 lbf ft.
10. Connect multiplug to IACV.
FUEL FILTER
WARNING: Spilling of fuel is unavoidable
during this operation. Ensure all
necessary precautions are taken to
WARNING: Ensure fuel handling
carrying out the following instructions.
Remove
1. Depressurise fuel system. See Adjustment,
fuel system depressurise
2. Clean area around hose connections to prevent
ingress of dirt into fuel system.
3. Clamp inlet and outlet hoses to reduce fuel
spillage when disconnecting.
4. Loosen 2 unions and disconnect hoses from fuel
filter.
5. Loosen bolt securing fuel filter to chassis
member.
6. Remove fuel filter.
Refit
7. Position NEW filter to chassis member,
observing direction of flow arrow stamped on
side.
8. Tighten bolt securing filter to chassis member.
9. Remove plugs.
10. Connect hoses to fuel filter and tighten unions to
30 Nm, 22 lbf ft.
11. Remove clamps from hoses.
12. Start engine and inspect for fuel leaks.
19
FUEL SYSTEM
16
REPAIR
FUEL PRESSURE REGULATOR
Remove
3. Release clip and disconnect fuel return hose
from fuel pipe.
4. Disconnect vacuum hose from pressure
regulator.
5. Remove 4 nuts securing coil mounting bracket to
inlet manifold.
6. Release coil mounting bracket from studs and
move aside.
7. Release regulator connecting pipe from clip.
8. Remove 2 bolts securing pressure regulator to
fuel rail.
9. Remove regulator from fuel rail.
11. Release clip and remove fuel hose from
regulator.
Refit
12. Clean mating faces of pressure regulator and
fuel rail.
13. Remove plugs from pressure regulator and fuel
rail.
14. Fit fuel hose to regulator and secure with clip.
15. Lubricate new pressure regulator O ring.
16. Fit regulator to fuel rail.
17. Connect fuel hose to pipe and secure with clip.
18. Fit bolts securing regulator to fuel rail and tighten
to 10 Nm, 7 lbf ft.
19. Position ignition coil mounting bracket to studs.
20. Fit nuts and tighten to 8 Nm, 6 lbf ft.
21. Remove plugs.
22. Connect fuel return hose and secure with clip.
23. Connect vacuum hose.
24. Remove cloth.
SFI
17
REPAIR
FUEL PUMP
Remove
2. Remove fuel tank. See fuel tank
3. Loosen clip and disconnect breather hose from
fuel pump.
4. Remove fuel feed and return hoses from fuel
pump.
5. Using tool LRT-19-001remove locking ring
securing pump. Withdraw fuel pump from fuel
tank.
WARNING: A quantity of fuel will be
retained in body of pump. Care must be
taken to prevent spillage during above
operation.
6. Remove and discard sealing ring.
Refit
7. Fit new sealing ring to pump and fit pump.
8. Fit locking ring and using tool LRT-19-001,
9. Fit feed and return hoses to pump.
10. Fit breather hose and tighten clip.
11. Fit fuel tank. See fuel tank; Refit
19
FUEL SYSTEM
18
REPAIR
FUEL TANK
WARNING: Ensure that fuel handling
carrying out following instructions.
CAUTION: Before disconnecting any part
of the fuel system, it is imperative that all
dust, dirt and debris is removed from
around components to prevent ingress of foreign
matter into fuel system.
Remove
4. Drain fuel tank. See Adjustment, fuel tank
drain
5. Loosen clip securing filler hose to fuel tank and
disconnect hose.
6. Loosen clip securing breather hose to filler neck
7. Using tool LRT-19-002 disconnect vapour
separator pipe at green end of speedfit
connector.
8. Position cloth to absorb fuel spillage.
SFI
19
REPAIR
9. Disconnect fuel feed hose union.
10. Disconnect fuel return hose union.
11. Loosen 2 anti-roll [sway] bar link bolts.
12. Mark location of anti-roll [sway] bar straps.
13. Remove 4 bolts securing anti-roll [sway] bar
straps and swing bar down clear of fuel tank.
14. Position transmission jack under fuel tank cradle
to support fuel tank.
rubber pad to protect fuel tank.
15. Remove 6 bolts securing fuel tank cradle.
16. Lower fuel tank sufficiently to gain access to fuel
pump multiplug.
17. Disconnect multiplug and remove clip securing
harness to fuel hoses.
18. With assistance, lower jack, remove fuel tank
cradle and fuel tank.
19. Remove 3 screws securing heat shield. Remove
heat shield.
20. Release 2 fuel cut-off valves and remove valve
and pipe assembly. Remove and discard 2
rubber seals.
21. Loosen clip and remove breather hose from fuel
pump.
22. Remove fuel feed and return hoses from fuel
pump.
19
FUEL SYSTEM
20
REPAIR
23. Using tool LRT-19-001 remove locking ring
securing pump. Withdraw fuel pump from tank.
WARNING: A quantity of fuel will be
retained in body of pump. Care must be
taken to prevent fuel spillage during above
operation.
24. Remove and discard sealing ring.
25. Fit new sealing ring to pump and fit pump.
26. Fit locking ring and using tool LRT-19-001,
27. Fit fuel feed and return hoses to pump.
28. Fit breather hose and tighten clip.
29. Fit new fuel cut-off valve seals.
30. Fit valve and pipe assembly.
31. Fit heat shield.
Refit
32. With assistance, locate fuel tank and position
cradle.
33. Position jack to support tank.
34. Connect fuel pump multiplug.
35. Raise jack, align cradle and fit and tighten bolts.
36. Raise anti-roll [sway] bar, align straps and fit and
tighten bolts.
37. Tighten anti-roll [sway] bar link bolts
38. Clean fuel pipes, connect pipes and tighten
unions.
39. Secure harness to fuel pipes with clip.
40. Connect vapour separator pipe.
41. Connect breather hose to filler neck and tighten
hose clip.
42. Connect filler hose to fuel tank and tighten hose
clip.
44. Run engine and check for leaks.
SFI
21
REPAIR
FUEL RAIL
Remove
3. Remove ram housing. See ram housing
4. Disconnect 8 injector multiplugs.
5. Disconnect fuel temperature sensor multiplug.
6. Position cloth around fuel feed pipe union to
absorb any fuel spillage.
7. Disconnect fuel feed pipe from fuel rail.
8. Plug fuel pipe and rail.
9. Loosen clip securing fuel return hose to fuel rail
10. Plug hose and rail.
11. Remove cloth.
12. Remove 6 nuts securing fuel rail and ignition coil
mounting bracket to inlet manifold.
13. Release ignition coil mounting bracket from inlet
manifold studs and move aside.
14. Release fuel rail and injectors from inlet
manifold.
15. Remove fuel rail and injectors.
16. Remove 2 bolts securing regulator to fuel rail.
17. Remove regulator.
19. Remove 8 clips securing injectors to fuel rail.
20. Remove injectors from fuel rail.
21. Remove and discard O rings from injectors.
22. Clean lower mating faces on ram housing and
manifold.
23. Lubricate new O rings.
24. Fit NEW O rings to injectors. Lightly coat O
rings with silicone grease.
25. Fit injectors to fuel rail.
26. Fit clips securing injectors to fuel rail.
CAUTION: Care must be taken when
refitting the fuel rail and injectors to inlet
manifold to prevent damage to O rings.
27. Lubricate NEW O ring of fuel regulator with
silicone grease.
28. Fit O ring.
29. Fit regulator to fuel rail and tighten bolts to 10
Nm, 7 lbf ft.
Refit
30. Position fuel rail.
31. Secure fuel rail.
32. Position coil bracket.
33. Fit nuts securing coil bracket and fuel rail and
tighten to 8 Nm, 6 lbf ft. .
34. Remove plugs from fuel feed and return pipes
and fuel rail.
35. Connect return hose and secure with clip.
36. Clean feed pipe union.
37. Connect fuel feed pipe and tighten union to 16
Nm, 11 lbf ft.
38. Connect injector and fuel temperature sensor
multiplugs.
39. Fit ram housing. See ram housing; Refit
19
FUEL SYSTEM
22
REPAIR
RAM HOUSING
Remove
2. Remove plenum chamber. See plenum
chamber
3. Disconnect 3 hoses from ram housing.
4. Remove 6 bolts securing ram housing to inlet
manifold.
5. Using a suitable lever and a block of wood,
release ram housing from inlet manifold.
Remove ram housing.
CAUTION: Do not use a mallet to break
sealant joint with inlet manifold.
6. Place a protective cover over inlet bores to
prevent ingress of dirt.
Refit
7. Clean mating faces of inlet manifold and ram
housing.
8. Apply Hylomar sealant to inlet manifold face.
9. Fit ram housing to inlet manifold.
NOTE: The ram housing can be fitted the
wrong way round. Ensure fuel pressure
regulator hose connection is on correct
side when refitting.
10. Tighten ram housing bolts, working from 2 centre
bolts, diagonally towards 4 outer bolts to 24 Nm,
18 lbf ft.
11. Connect hoses to ram housing.
12. Fit plenum chamber. See plenum chamber;
Refit
SFI
23
REPAIR
WHEEL SPEED SENSOR - FRONT
Remove
CAUTION: If a sensor is removed for any
reason, a NEW sensor bush and seal must
be fitted.
2. Release wheel speed sensor multiplug from clip
on inner wing [fender] and disconnect.
3. Raise vehicle on 4 post ramp.
4. Release cable ties securing sensor harness to
chassis and front axle.
5. Clean area around sensor to prevent possible
ingress of dirt.
6. Using a suitable lever, release sensor from
mounting bush.
7. Remove sensor.
8. Position container to collect any brake fluid.
9. Clamp flexible brake hose to caliper.
10. Using 2 spanners, loosen brake pipe to hose
union and disconnect.
CAUTION: Do not allow brake fluid to
contact paint finished surfaces as paint
may be damaged. If spilled, remove fluid
and clean area with clean warm water.
11. Remove nut securing brake pipe to mounting
bracket.
12. Release brake hose from mounting bracket.
13. Remove 2 bolts securing bush retaining plate to
top of hub.
14. Release retaining plate from mud shield and
remove.
15. Remove and discard seal and bush from hub.
Refit
16. Ensure sensor bush and seal mating faces are
clean.
17. Fit sensor bush and seal to hub.
18. Fit retaining plate to hub and secure with bolts.
CAUTION: Apply Loctite 270 to retaining
plate bolts.
19
FUEL SYSTEM
24
REPAIR
19. Position brake hose to mounting bracket and
secure with nut.
20. Connect brake pipe to hose and, using 2
spanners, tighten union.
21. Remove clamp from brake hose.
22. Ensure sensor body is clean and coat with EP
90 oil.
23. Fit sensor through bush until it contacts the
reluctor ring. The sensor will be knocked-back
to the correct position when the vehicle is driven.
24. Route sensor lead up through engine
compartment and secure cable ties.
25. Lower vehicle.
26. Connect sensor multiplug and secure to clip.
28. Bleed brake system. See BRAKES, Repair,
brake system bleed
WHEEL SPEED SENSOR - REAR
Remove
CAUTION: If a sensor is removed for any
reason, a NEW sensor bush and seal must
be fitted.
2. Raise rear of vehicle.
WARNING: Support on safety stands.
3. Remove both rear road wheels.
4. Disconnect sensor multiplugs at RH side of
chassis.
5. Release cable ties securing sensor harness to
rear suspension and axles.
SFI
25
REPAIR
6. Release sensor harness from clips on rear axle.
7. Remove 6 bolts, 3 each side, securing rear
wheel brake caliper mud shields.
8. Remove mud shields and clear area around
sensor to prevent possible ingress of dirt.
9. Using a suitable lever, release sensors from
mounting bushes.
10. Remove sensors.
11. Remove and discard sensor bushes.
Refit
12. Ensure NEW sensor bushes and housings are
clean, then fit bushes.
13. Ensure sensor bodies are clean and lightly coat
with EP 90 lubricant.
14. Fit sensors through bushes until they contact the
reluctor ring. The sensors will be knocked-back
to the correct position when the vehicle is driven.
15. Secure sensor harness to rear axle clips.
16. Secure sensor harness to rear suspension and
axle with cable ties.
17. Connect sensor harness multiplugs.
18. Position rear brake caliper mud shields and
secure with bolts.
19. Fit rear road wheels.
20. Remove stand(s) and lower vehicle.
19
FUEL SYSTEM
26
REPAIR
ECU - ROUGH ROAD DETECTION
Remove
2. Release front edge of passenger seat cushion
and remove cushion.
3. Release clip and remove ECU cover plate.
4. Remove 2 bolts securing ECU to mounting
bracket and collect nuts.
5. Remove ECU from mounting bracket and
disconnect multiplug.
6. Remove ECU.
Refit
7. Fit ECU, connect multiplug and position to
mounting bracket.
8. Secure ECU mounting bracket with nuts and
bolts.
9. Fit ECU cover plate and secure with clip.
10. Position rear edge of passenger seat cushion to
seat frame and secure front edge to clips.
SFI
1
TORQUE SETTNGS
Nm lbf ft
Intake air temperature (IAT) sensor 8 ................................. 6
Crank position sensor 8 ...................................................... 6
Coolant temperature sensor 20 ............................................. 15
Fuel filter 30 .......................................................................... 20
Fuel pressure regulator 10 .................................................... 7
Coil bracket 8 ...................................................................... 6
Fuel feed pipe 16 .................................................................. 12
Ram housing to manifold 24 ................................................. 18
Fuel temperature sensor 17 .................................................. 13
Throttle position sensor 2 .................................................... 1.5
Knock sensor 16 ................................................................... 12
Idle air control valve 2 ......................................................... 1.5
Water jacket 13 ..................................................................... 10
Throttle bracket 8 ................................................................ 6
Plenum chamber 24 .............................................................. 18
Inlet manifold 38 .................................................................... 28
Camshaft position sensor 8 ................................................. 6
Heated oxygen sensors 20 ................................................... 15
Fuel pump locking ring 48 ..................................................... 35
COOLING SYSTEM
1
ENGINE COOLING
Description
The V8i engine uses a pressurised cooling system
and cross flow radiator which is supplied from a
separate expansion tank. The coolant radiator also
incorporates a section at the side for cooling the
engine oil. The transmission fluid cooler is mounted
below the radiator.
The belt driven viscous fan and centrifugal water
pump is located in the engine front cover with ports for
circulation of coolant to both banks of cylinders and
cylinder heads. Coolant returns to the top of the
radiator via ports in the inlet manifold where the
thermostat is mounted horizontally.
Coolant also circulates through the vehicle heating
system and is used to heat air entering the inlet
manifold plenum chamber.
Coolant circulation (engine hot)
1. Cross flow radiator
2. Expansion tank
3. Viscous fan and water pump
4. Heater pipes
5. Thermostat
6. Plenum chamber connection
26
COOLING SYSTEM
2
COOLANT CIRCULATION
Operation
When the engine is started from cold the thermostat
prevents any coolant circulation through the radiator
by closing off the top hose. During the engine warm
up period, the water pump, pumps coolant around the
cylinders to the rear of the cylinder block along the
main galleries in both cylinder banks. At the rear of
the cylinder block the coolant rises through a large
port in each cylinder head/block joint face, and then
flows forward to connect with ports at the front of the
inlet manifold. From the manifold the coolant is carried
by an external pipe to the heater unit and from the
heater through another external pipe to the pump
inlet.
The coolant circulation through the cylinder block and
heads, does not change when normal running
temperature is reached and the thermostat opens. But
with the thermostat open, coolant also flows through
the top hose to the radiator where it is cooled and
drawn back into the pump via the bottom hose.
Throttle housing heating
The base of the throttle housing is heated by a flow of
coolant from the inlet manifold which returns through a
long hose, to the top right corner of the radiator. The
throttle housing is heated to prevent throttle disc icing.
COOLING SYSTEM
3
VISCOUS FAN
Description
The viscous drive unit for the engine cooling fan,
provides a means of controlling the speed of the fan
relative to the running temperature of the engine. The
viscous unit is a type of fluid coupling, which drives
the fan blades by means of silicone fluid.
1. Input (drive) member
2. Output (driven) member
3. Sensing mechanism (bi-metal coil)
The fan drive has to be engaged only periodically,
between 5% and 10%, during normal operating
conditions, because the engine is cooled by ram air
for most of the time.
Operation
To engage and disengage the fan drive the bi-metal
coil senses air temperature behind the radiator. When
a pre-determined temperature is reached, the coil
opens a valve (5) which allows fluid to enter the drive
area and, due to centrifugal force, circulates to the
annular drive area.
There are two sets of annular grooves (3), one in the
drive clutch and the other in the drive body, a specific
clearance being provided between the two sets of
grooves.
Viscous unit disengaged (engine at normal
running temperature)
1. Input (drive) member
2. Output (driven) member
3. Running clearance
4. Pump plate
5. Valve (closed)
6. Sensing mechanism (bi-metal coil)
7. Fluid seal
8. Bearing, input member
9. Fluid chamber
10. Fluid reservoir
26
COOLING SYSTEM
4
When this clearance is filled with viscous fluid, a
shearing action, caused by the speed differential
between the two drive components, transmits torque
to the fan. The fluid is thrown to the outside of the unit
by centrifugal force from where it is recirculated to the
reservoir (10) via the pump plate (4) adjacent to the
drive member.
If the engine speed is increased the amount of slip will
also increase to limit the maximum fan speed.
When the air temperature from the radiator drops
sufficiently, the bi-metal coil closes the valve and
prevents fluid entering the drive area. The fluid that is
in the drive area will gradually pump out into the
reservoir (10) and the fan will return to an idle
condition.
Viscous unit engaged (hot running temperature)
Bi-metal coil (6) expanded, valve (5) open.
COOLING SYSTEM
1
FAULT DIAGNOSIS
ENGINE OVERHEATING
Before conducting any cooling system diagnosis: See
Description and operation, Engine Cooling
1. Is coolant level correct?
NO - Allow engine to cool, top up level to
expansion tank seam.
YES - Continue.
2. Is coolant in radiator frozen?
YES - Slowly thaw and drain system. See
Adjustment, Coolant Requirements
NO - Continue.
3. Is air flow through radiator restricted or blocked?
YES - Apply air pressure from engine side of
radiator to clear obstruction.
NO - Continue.
4. Are there any external leaks, from hoses,
coolant pump, engine gaskets or the heater unit?
YES - Investigate and rectify. See Adjustment,
Coolant Requirements
NO - Continue.
5. Are fan blades fitted correct way round, concave
side towards engine?
NO - Rectify.
YES - Continue.
6. Is viscous unit operating correctly? See
Description and operation, Viscous Fan
NO - Renew. See Repair, Viscous Coupling
YES - Carry out a pressure test on radiator cap
and system. Check thermostat type,
operation and correct fitting See Repair,
Thermostat
7. Is temperature sender and gauge giving
accurate readings?
NO - Substitute parts and compare readings.
YES - Continue.
8. Carry out cylinder pressure test to determine if
pressure is leaking into cooling system causing
over pressurising and loss of coolant.
If problem is not diagnosed, check the coolant system
for engine oil contamination and engine lubrication
system for coolant contamination.
If the coolant only, or both systems are contaminated,
suspect cylinder head gaskets or radiator.
If only the lubrication stystem is contaminated with
coolant, suspect inlet manifold or front cover gaskets.
26
COOLING SYSTEM
2
FAULT DIAGNOSIS
ENGINE RUNS COLD
Before conducting any cooling system diagnosis: See
Description and operation, Engine cooling
1. Check operation of viscous unit. See
Description and operation, Viscous Fan
Is viscous unit operating correctly?
NO - See Repair, Viscous coupling
YES - Continue.
2. Is thermostat correct type and operating? See
Repair, Thermostat
If problem is not diagnosed: Continue.
3. Are the air conditioning fans operating
continuously?
YES - See Electrical Trouble Shooting
Manual.
NO - Continue.
4. Is temperature sender and gauge giving
accurate readings? Substitute parts and
compare readings. If problem is not diagnosed
repeat tests, starting at 1.
COOLING SYSTEM
1
ADJUSTMENT
COOLANT REQUIREMENTS
Frost precautions and engine protection.
Cooling system MUST ALWAYS be filled and
topped-up with solution of water and anti-freeze,
winter and summer. NEVER use water alone, this
may corrode aluminium alloy.
CAUTION: Do not use salt water otherwise
corrosion will occur. In certain territories
where only available natural water supply
has some salt content use only rain or distilled
water.
Recommended solutions
Anti-freeze: Universal anti-freeze or permanent type
ethylene base, without methanol, containing a suitable
inhibitor for aluminium engines and engine parts. See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Anti-freeze
Use one part of anti-freeze to one part of water.
Anti-freeze can remain in the cooling system and will
provide adequate protection for two years provided
that specific gravity of coolant is checked before onset
of second winter and topped-up with new anti-freeze
as required.
Vehicles leaving factory have cooling system filled
with 50% solution of anti-freeze and water. This gives
protection against frost down to minus 36C, minus
33F. Vehicles so filled are identified by a label affixed
to radiator.
NOTE: Should ambient temperatures be
below that stated above refer to
Anti-Freeze Data in Recommended
Lubricants, Fluids and Capacities in Section 09.
Instructions in chart must be strictly adhered to
before driving vehicle.
After the second winter the system should be drained
and thoroughly flushed. Before adding new anti-freeze
examine all joints and replace defective hoses to
make sure that the system is leakproof.
For protection quantities. See LUBRICANTS,
anti-freeze
DRAIN AND REFILL
Drain
WARNING: Do not remove expansion tank
filler cap when engine is hot. The cooling
system is pressurised and personal
scalding could result. See coolant requirements
before refilling system.
1. Remove expansion tank filler cap by slowly
turning it anti-clockwise. Pause to allow pressure
to escape. Continue turning it in same direction
and remove.
2. Remove viscous coupling. See Repair,
viscous coupling
3. Remove radiator filler plug and O ring to assist
drainage.
4. Position container to collect coolant spillage.
5. Loosen clip securing hose to coolant pump.
6. Release hose from coolant pump and allow
coolant to drain.
26
COOLING SYSTEM
2
ADJUSTMENT
NOTE: It is not possible to drain all coolant
retained in heater system.
7. Remove engine drain plugs beneath exhaust
manifolds and allow coolant to drain from
engine.
Refill
1. Fit drain plugs to engine.
2. Connect hose to coolant pump and secure with
clip.
3. Fit viscous coupling. See Repair, viscous
coupling
4. Pour correct solution of water and anti-freeze
into expansion tank until radiator is full.
5. Start engine and run until normal operating
temperature is reached.
6. Top up coolant level as necessary.
7. Fit new O ring to radiator filler plug.
8. Fit radiator filler plug and tighten to 6 Nm, 4 lbf
ft.
9. Fit expansion tank filler cap.
10. Allow engine to cool and check coolant level.
11. Top-up expansion tank until level reaches seam.
12. Remove container.
COOLING SYSTEM
1
REPAIR
EXPANSION TANK
Remove
WARNING: Do not remove expansion tank
filler cap when engine is hot. The cooling
system is pressurised and personal
scalding could result.
1. Remove expansion tank filler cap by slowly
turning it anti-clockwise. Pause to allow pressure
to escape then continue to turn in same direction
and remove.
2. Position container to collect any coolant spillage.
3. Loosen clip securing radiator hose to expansion
tank.
4. Release radiator hose from expansion tank.
5. Loosen clip securing coolant hose to underside
of expansion tank.
6. Release coolant hose from expansion tank.
7. Remove overflow pipe from expansion tank.
8. Remove clamping bolt from expansion tank
mounting bracket and collect nut and washer.
9. Lift mounting bracket clamp and remove
expansion tank.
Refit
10. Fit expansion tank to mounting bracket.
11. Fit and tighten nut and bolt securing expansion
tank to mounting bracket.
12. Fit overflow pipe to expansion tank.
13. Connect coolant hose to underside of expansion
tank and secure with clip.
14. Connect radiator hose to expansion tank and
secure with clip.
16. Top-up engine coolant.
VISCOUS COUPLING
Remove
2. Remove 2 screws securing radiator top
mountings to fan upper cowl.
3. Release 2 clips securing fan upper cowl to lower
cowl.
4. Remove fan upper cowl.
26
COOLING SYSTEM
2
REPAIR
5. Position tool LRT-12-093 to hold coolant pump
pulley.
6. Loosen viscous coupling nut using tool
LRT-12-094.
7. Remove tool LRT-12-093.
8. Remove viscous coupling assembly.
9. Remove 4 Allen screws securing fan blades to
coupling.
10. Remove fan blades from coupling.
Refit
11. Clean mating faces of fan blades and coupling.
12. Fit fan blades to coupling and secure with Allen
screws.
13. Position coupling assembly and start tightening
nut.
14. Position tool LRT-12-093 to hold pulley.
15. Tighten viscous coupling assembly nut using
tool LRT-12-094.
16. Remove tools.
17. Fit fan upper cowl and secure with clips.
18. Align fan cowl fixings to upper mounting brackets
COOLING SYSTEM
3
REPAIR
RADIATOR
Remove
2. Drain cooling system. See Adjustment, drain
and refill
3. Remove 8 screws securing front grille to body.
4. Remove front grille.
5. Remove 4 bolts securing radiator top mountings
to bonnet locking panel and collect nuts.
6. Remove radiator top mountings.
7. Remove fan cowl upper mounting brackets.
8. Loosen clip and disconnect top hose from
radiator.
9. Remove 2 clips securing fasn cowl to radiator.
26
COOLING SYSTEM
4
REPAIR
10. Remove fan cowl.
11. Loosen clip and disconnect throttle body to
radiator hose.
12. Loosen clip and disconnect expansion tank to
radiator hose.
13. Position container beneath engine oil cooler pipe
unions.
14. Loosen engine cooler pipes and disconnect from
radiator.
15. Remove and discard O rings from oil cooler
pipes.
16. Plug oil cooler pipe connections.
17. Loosen clip and disconnect bottom hose from
radiator.
18. Release radiator from lower mounting rubbers
and remove radiator.
Refit
19. Fit radiator and secure to lower mounting
rubbers.
NOTE: Ensure condenser lower mounting
brackets are located to radiator lower
mounting brackets.
20. Connect bottom hose to radiator and secure with
clip.
21. Remove plugs from engine oil cooler pipe
connections.
22. Clean oil cooler pipe connections.
23. Lubricate NEW O rings with clean engine oil
and fit to pipes.
24. Connect oil cooler pipes to radiator and tighten
unions to 30 Nm, 22 lbf ft.
26. Connect expansion tank hose to radiator and
tighten clip.
27. Connect throttle body hose to radiator and
tighten clip.
28. Fit fan cowl to radiator.
29. Fit fan cowl lower retaining clips.
30. Connect top hose to radiator and tighten clip.
31. Fit fan upper cowl and secure with clips.
32. Fit fan cowl upper mounting brackets.
33. Fit radiator top mountings and secure with
screws and bolts.
34. Fit front grille and secure with screws.
35. Refill cooling system. See Adjustment, drain
and refill
COOLING SYSTEM
5
REPAIR
THERMOSTAT
Remove
and refill
3. Loosen clip and disconnect radiator top hose
from coolant outlet elbow.
4. Remove 2 bolts securing coolant outlet elbow to
engine.
5. Remove coolant outlet elbow and collect gasket.
6. Remove thermostat.
Refit
7. Fit thermostat ensuring jiggle pin/vent hole is
uppermost.
8. Fit coolant outlet elbow with new gasket.
9. Fit and tighten bolts securing coolant outlet
elbow to 28 Nm, 21 lbf ft.
10. Connect radiator top hose to coolant outlet
elbow tighten clip.
and refill
COOLANT PUMP
Remove
and refill
2. Loosen coolant pump pulley bolts.
3. Release auxillary drive belt tension by turning
tensioner clockwise.
4. With tension released, remove belt from
alternator pulley.
NOTE: If belt is to be refitted, mark
direction of rotation.
6. Remove bolts securing coolant pump pulley.
7. Remove coolant pump pulley.
26
COOLING SYSTEM
6
REPAIR
8. Noting their fitted positions, remove 9 bolts
securing coolant pump.
9. Remove coolant pump.
10. Remove gasket.
Refit
11. Clean coolant pump and timing cover mating
faces.
12. Lightly grease NEW gasket and position to
timing cover.
13. Clean threads of all long bolts and coat with
Loctite 572 thread sealant.
14. Position coolant pump, fit bolts and tighten to 28
Nm, 21 lbf ft.
15. Fit coolant pump pulley, fit bolts but do not
tighten.
16. Clean auxillary drive belt pulley grooves and
inspect for damage.
17. Fit belt to pulleys.
18. Turn drive belt tensioner clockwise and engage
belt on alternator pulley.
19. Release drive belt tensioner.
20. Tighten coolant pump pulley bolts.
and refill
COOLING SYSTEM
1
TORQUE VALUES
Nm lbf ft
Oil cooler pipes 30 ................................................................ 22
Radiator filler plug (plastic) 6 ............................................... 4.5
MANIFOLD AND EXHAUST SYSTEM
1
CATALYTIC CONVERTERS - V8i
Description
Catalytic converters which form part of the engine
emission control system, are designed to clean the
exhaust gases, by chemically converting pollutant
elements in the exhaust to gases less harmfull to the
environment.
1. Catalysts
2. Oxygen sensors
The front section of the exhaust system from each
cylinder bank contain the ceramic elements of the
catalytic converters. The oxygen sensors, which
transmit information to the fuel ECM for control of the
mixture, are located in the exhaust down pipes.
The Hydrocarbons (HC), Nitogen oxides (NO
x
) and
Carbon monoxide (CO) emitted by the engine react
with the catalytic element and exhaust temperature to
convert the toxic gas, into Nitrogen (N2), Carbon
dioxide (CO
2
) and water vapour (H
2
O).
The sophisticated closed loop control system ensures
that mixture is always kept at the optium level for peak
catalyst efficiency. Also, the advanced On Board
Diagnostics ensure that any faults likely to cause
damage to the catalyst are indicated to the driver.
However, should the engine be supplied with a rich
mixture causing high CO in the exhaust gas, the
ceramic element will become coated and the useful
life of the catalyst reduced. If the mixture is too weak,
excess oxygen in the exhaust gas will cause the
catalysts to burn out. Similarly, should a cylinder
misfire occur, the unburnt fuel and unburnt oxygen
can cause a catalyst burn out.
CAUTION: The catalyst matrices are fragile
ceramic honeycombs which can become
damaged if roughly treated. Do not use a
hammer or mallet when working on the exhaust
system.
1
REPAIR
INTERMEDIATE PIPE
Remove
2. Release intermediate pipe from mounting
rubber.
3. Remove 2 nuts securing intermediate pipe to tail
pipe.
4. Remove 2 nuts securing intermediate pipe to
front pipe.
5. Release intermediate pipe from front and tail
pipes and remove.
Refit
6. Fit intermediate pipe to front and tail pipes.
7. Secure intermediate pipe to mounting rubber.
8. Fit and tighten nuts securing intermediate pipe to
front pipe, 30 Nm, 22 lbf ft.
9. Fit and tighten nuts securing intermediate pipe to
tail pipe, 30 Nm, 22 lbf ft.
10. Lower vehicle.
TAIL PIPE
Remove
1. Raise vehicle on a ramp [hoist].
2. Remove 2 nuts securing tail pipe to intermediate
pipe.
3. Release tail pipe from mounting rubber.
4. Release tail pipe from intermediate pipe and
feed over rear axle.
5. Remove tail pipe.
Refit
6. Feed tail pipe over rear axle and connect to
intermediate pipe.
7. Secure tail pipe to mounting rubber.
8. Fit nuts and tighten tail pipe to intermediate pipe.
30 Nm, 22 lbf ft.
9. Lower vehicle.
1
TORQUE VALUES
MANIFOLDS AND EXHAUSTS - V8i
Nm lbf ft
Inlet manifold to cylinder head 38 ......................................... 28
Exhaust manifold to cylinder head 20 ................................... 15
Exhaust front pipe to manifold 45 .......................................... 33
Exhaust front pipe to intermediate pipe 30 ............................ 22
Exhaust intermediate pipe to rear pipe 30 ............................ 22
TRANSFER GEARBOX
1
LT230Q TRANSFER GEARBOX
Description
The LT230Q transfer gearbox is a permanent 4 wheel
drive, two speed ratio reducing gearbox, incorporating
high and low range outputs with mechanically lockable
centre differential (diff-lock). High/low range and
diff-lock selection are made via a single lever located
forward of the main gear lever.
The transfer gearbox is mounted at the rear of the
main gearbox, the mainshaft of which extends into the
transfer casing. A transfer gear, supported on taper
roller bearings and splined to the gearbox mainshaft,
passes the drive to an intermediate gear cluster
supported on a single shaft and rotating on taper roller
bearings.
The intermediate gears pass the drive to high and low
speed gears on the rear output shaft. The rear output
shaft passes through the speed transducer drive
housing, which also forms the mounting for the park
brake. A worm gear fitted to the rear output shaft
drives a pinion fitted in the speed transducer housing.
Integral with the output shafts is a differential
assembly which compensates for speed differences
between the front and rear prop shafts. To prevent all
the power being transmitted to the axle offering the
least resistance, a diff-lock is provided. Selection of
differential lock engages, through mechanical linkage,
a dog clutch with the front output shaft, this action
locks the centre differential and provides a fixed drive,
giving equal power to the front and rear output shafts.
41
TRANSFER GEARBOX
2
The diff-lock should only be engaged during severe
off-road conditions and should be disengaged as soon
as conditions permit.
A shiftlock device, used as a park facility, is fitted and
prevents accidental gear disengagement when the
ignition is switched off. An audible neutral alarm is
also fitted to alert the driver, when parking, to move
the gear lever to the high or low position.
TRANSFER GEARBOX
1
FAULT DIAGNOSIS
LT230Q TRANSFER GEARBOX - OIL SEAL
LOCATIONS
1. Input seal.
2. Cover plate joints.
3. Front output seal.
4. Front and rear housing joint faces.
5. Rear output seal.
6. Power take off cover plate joint.
7. Bearing plate joint.
41
TRANSFER GEARBOX
2
FAULT DIAGNOSIS
OIL LEAKS
Verify that oil leak is from transfer box and not main
gearbox before proceeding with checks.
Prior to road test
1. Check oil level in transfer box is correct.
2. Check tightness of level and drain plugs.
3. Check breather system for blockage. To validate
system pipe must be removed, inspected,
rectified as necessary and refitted.
4. Remove all traces of oil from exterior of transfer
box.
Take vehicle for short road test.
1. Identify source of leaks and rectify as follows.
Front or rear output seal leaking:-
1. Drain oil and remove leaking output flange.
2. Inspect seal track on flange for surface damage.
If damaged renew component.
3. Remove and discard oil seal.
4. Inspect seal locating bore and remove any sharp
edges which may damage new oil seal.
5. Fit new seal.
6. Fit output flange and all other parts.
7. Add oil to correct level into gearbox. See
Information, Recommended Lubricants and
Fluids
Cover plate sealant leaking.
1. Drain oil and remove leaking cover plate.
2. Remove all traces of joint sealant from both joint
faces.
3. Degrease all components and apply a thin film of
Hylomar sealant, to both joint faces.
4. Apply thread sealant to bolts which come into
contact with gearbox oil.
5. Refit cover plate.
CAUTION: Care must be taken not to
overtighten fixings.
Leak between main and transfer gearboxes.
1. Site vehicle onto a ramp [hoist].
2. Select neutral in transfer box and select 4th gear
in main gearbox.
3. Run engine at 2000 rpm with clutch/drive
engaged.
4. Observe joint between main and transfer boxes.
5. If oil leak is found establish if it is gear oil.
6. If so, leak is originating from transfer box.
7. Check two inner (main/transfer) bolts are oil
tight, as these holes are tapped into the main
transfer case.
8. Remove transfer box to inspect mainshaft collar
seal track condition, and front face of transfer
case for porosity. See Repair, LT230Q
Transfer Gearbox
9. If these areas require servicing, transfer gearbox
input seal must also be renewed.
CAUTION: Avoid damaging new seal lip
and ensure seal is fitted flush with
machined face. Also ensure new seal is
not damaged when refitting transfer gearbox.
10. If red A.T.F type oil is seen leaking during
workshop test, investigate main gearbox for
cause of leak.
Detent plug or electrical switch leaks.
1. Detent plugs and electrical switches do not
usually leak. It must be noted that they fit into
open tapped holes in transfer case and therefore
should be considered when looking for source of
leak.
TRANSFER GEARBOX
1
REPAIR
LT230Q TRANSFER GEARBOX
Service repair no - 41.20.25/99
Remove
The transfer gearbox should be removed from
underneath the vehicle, using a hydraulic hoist and
adaptor plate LRT-99-010.
WARNING: Where use of a transmission
hoist is necessary, it is absolutely
essential to follow the manufacturers
instructions to ensure safe and effective use of
the equipment.
1. Position vehicle on a ramp [hoist].
2. Select LOW range gear and leave vehicle in
neutral.
4. Remove centre console. See CHASSIS AND
BODY, Repair, centre console
5. Remove carpet from transmission tunnel.
6. Remove high-low selector housing cover from
transmission tunnel.
7. Remove 3 trim studs securing handbrake lever
gaiter.
8. Release handbrake lever gaiter for access to
handbrake cable linkage.
41
TRANSFER GEARBOX
2
REPAIR
9. Remove split [cotter] pin and clevis pin securing
handbrake cable to lever.
10. Remove 2 screws securing fan cowl to upper
retaining brackets.
11. Release 2 clips securing upper fan cowl.
12. Remove upper fan cowl.
14. Drain transfer gearbox oil. See SECTION 10,
15. Remove exhaust front pipe. See EMISSION
CONTROL, Repair, front pipe/catalytic
converter
pipe.
17. Release intermediate pipe from tail pipe and
remove from mounting.
18. Remove 8 bolts securing chassis crossmember.
19. With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable removal of crossmember.
20. Remove crossmember.
21. Remove body jack.
TRANSFER GEARBOX
3
REPAIR
22. Using a centre punch, mark relationship between
front propeller shaft and transfer box drive
flanges and rear propeller shaft and brake drum
drive flanges.
23. Remove 4 nuts securing front propeller shaft to
transfer box flange. Release propeller shaft from
flange and tie aside.
24. Remove 4 nuts securing rear propeller shaft to
brake drum flange. Release propeller shaft from
flange and tie aside.
25. Remove nut securing tie bar to gear box and 2
bolts securing tie bar to transfer box.
26. Remove tie bar.
27. Remove bolt securing selector outer cable clamp
to transfer gearbox LH mounting.
28. Remove nut securing oxygen sensor multiplug
bracket to transfer gearbox earth bolt and collect
bracket.
29. Remove nut securing earth strap to transfer
gearbox and release strap.
41
TRANSFER GEARBOX
4
REPAIR
30. Release handbrake outer cable from body.
31. Remove bolt securing ground lead to RH side of
transfer gearbox.
32. Remove bolt securing handbrake cable heat
shield. Remove heat shield.
33. Position adaptor plate, LRT-99-010, and secure
to transmission hoist with 4 bolts.
34. Remove 4 central bolts from transfer gearbox
bottom cover, move hoist into position and
secure adaptor plate to transfer box.
35. Adjust hoist to take weight of transfer gearbox.
36. Remove 2 nuts and bolts securing heat shield to
transfer gearbox LH mounting bracket. Remove
heat shield.
37. Remove 3 nuts and bolts securing LH gearbox
mounting bracket to chassis.
TRANSFER GEARBOX
5
REPAIR
38. Remove nut securing transfer gearbox RH
mounting to mounting rubber.
39. Remove 3 nuts and bolts securing transfer
gearbox mounting bracket to chassis. Remove
transfer box RH mounting bracket and collect
rubber mounting heat shield.
40. Lower transmission sufficiently to gain access to
harness connectors and transfer box breather
pipe connection.
41. Remove banjo bolt from transfer box breather
pipe and collect 2 sealing washers. Discard
sealing washers.
42. Remove retaining clip and disconnect high/low
lever from operating rod.
43. Remove 2 clips at lower end of pivot arm and
disconnect differential lock lever link.
44. Disconnect the following multiplugs/connectors
from transfer box:
Speed transducer
Parking solenoid
Neutral detection switch
Differential lock
Temperature sensor switch
45. Remove 2 clips securing harness to transfer box.
46. Position a jack to support main gearbox.
rubber pad to protect gearbox.
47. Remove nut and 4 bolts securing transfer box to
main gearbox extension case.
48. Fit 3 guide studs, LRT-41-009, through transfer
box bolt holes to support it during removal.
49. Lower hoist and withdraw transfer box from main
gearbox.
50. Remove transfer box.
Refit
51. Ensure joint faces of transfer box and main
gearbox are clean and guide studs, LRT-41-009,
are fitted to extension case.
52. Lubricate oil seal in joint face of transfer box.
53. Secure transfer box to adaptor plate on lifting
hoist and raise hoist until transfer box can be
located over guide studs.
54. Remove guide studs, and secure transfer box to
main gearbox extension case. Tighten fixings to
45 Nm, 33 lbf/ft.
55. Connect muliplugs/connectors to transfer box.
56. Position breather pipe to transfer box, fit new
sealing washers and tighten banjo bolt to 15 Nm,
11 lbf ft.
57. Fit link to differential lock lever and pivot arm and
secure with retaining clips.
58. Connect high/low lever to operating rod and
secure with retaining clip.
59. Raise hoist and remove jack supporting main
gearbox.
60. Position RH mounting rubber heat shield and
mounting bracket and secure loosely with
retaining nut.
61. Align RH mounting bracket to chassis and
secure with nuts and bolts.
62. Tighten nut securing RH mounting.
63. Align LH mounting bracket to chassis and
secure with nuts and bolts.
NOTE: Position ground lead to mounting
bolt.
41
TRANSFER GEARBOX
6
REPAIR
64. Remove 4 bolts securing hoist adaptor plate to
transfer box bottom cover.
65. Lower hoist and move aside.
66. Clean threads of the 4 bolts, coat with Loctite
290, and fit to transfer box bottom cover. Tighten
to 25 Nm, 18 lbf/ft.
67. Position handbrake cable heat shield and tighten
bolt.
68. Position ground lead to RH side of transfer box
and tighten bolt.
69. Feed handbrake cable through body.
NOTE: Apply a soap solution to aid fitment
of cable.
70. Position ground strap to transfer box stud and
tighten nut.
71. Fit heated oxygen sensor multiplug bracket to
stud and tighten nut.
72. Position selector outer cable clamp to transfer
box LH mounting and tighten bolt.
73. Fit tie bar and tighten bolts and nut.
74. Clean rear propeller shaft and brake drum flange
mating faces.
75. Release propeller shaft, align flange markings
and connect to studs.
76. Fit nuts securing propeller shaft and tighten to 47
Nm, 33 lbf ft.
77. Clean front propeller shaft and transfer box
flange mating faces.
78. Release propeller shaft, align flange markings
and connect to studs.
79. Fit nuts securing propeller shaft and tighten to 47
Nm, 33 lbf ft.
enable fitment of crossmember.
81. Fit crossmember and tighten bolts.
82. Clean intermediate and tail pipe flanges.
83. Fit intermediate pipe to mounting rubber,
connect to tail pipe and tighten nuts.
84. Fit exhaust front pipe. See EMISSION
converter
85. Refill transfer box with recommended oil. See
SECTION 10, Maintenance, under vehicle
maintenance .
86. Lower vehicle ramp.
87. Fit upper fan cowl and secure clips.
88. Align fan cowl to upper retaining brackets and
tighten screws.
89. Align handbrake cable to lever, fit clevis pin and
secure with new split [cotter] pin.
90. Position handbrake lever cover and secure with
trim studs.
91. Fit high-low selector housing cover to
transmission tunnel.
92. Fit carpet to transmission tunnel.
93. Fit centre console. See CHASSIS AND BODY,
Repair, centre console
95. Check park brake operation and adjust if
necessary. See SECTION 10, Maintenance,
vehicle interior
TRANSFER GEARBOX
7
REPAIR
SHIFTLOCK SOLENOID
Remove
BODY, Repair, Centre console
3. Remove 2 screws securing relay panel.
4. Retain 2 centre console screw brackets and
spacers.
5. Release connector J1962 from bracket on tunnel
cover and move relay panel aside to gain access
to tunnel cover top fixings.
6. Remove 15 screws securing tunnel cover.
7. Release and remove tunnel cover.
8. Disconnect shiftlock solenoid multiplug.
9. Remove 4 bolts and release solenoid cover from
transfer box.
10. Remove solenoid and washer.
11. Clean joint sealant from mating faces.
Refit
12. Apply Hylosil or equivalent sealant to mating
faces.
13. Fit solenoid. Ensure solenoid multiplug lead is
located in cover recess.
14. Secure solenoid cover to transfer box. Tighten
bolts to 9 Nm (7 lbf/ft).
15. Connect solenoid multiplug.
16. Fit tunnel cover.
17. Secure connector J1962 to bracket on tunnel
cover.
18. Position centre console screw bracket and
spacers and fit relay panel.
19. Fit tunnel carpet.
Repair, Centre console
41
TRANSFER GEARBOX
8
REPAIR
NEUTRAL SWITCH
Remove
BODY, Repair, Centre console
3. Remove 2 screws securing relay panel.
4. Retain 2 centre console screw brackets and
spacers.
5. Release connector (J1962) from bracket on
tunnel cover and move relay panel aside to gain
access to tunnel cover top fixings.
6. Remove 15 screws securing tunnel cover.
7. Release and remove tunnel cover.
8. Disconnect neutral switch multiplug.
9. Remove neutral switch from transfer box.
10. Clean sealant from switch.
Refit
11. Apply Hylomar PL32/L20 or equivalent sealant to
neutral switch.
12. Fit switch to transfer box and tighten to 25 Nm
(18 lbf/ft).
13. Connect switch multiplug.
14. Fit tunnel cover.
15. Secure connector (J1962) to bracket on tunnel
cover.
16. Position centre console screw bracket and
spacers and fit relay panel.
17. Fit tunnel carpet.
Repair, Centre console
TRANSFER GEARBOX
1
TORQUE VALUES
LT230Q Transfer gearbox
Nm lbf ft
Bottom cover to transfer case 25 .......................................... 18
Transfer breather 15 ............................................................. 11
Transfer box front drive flange to drive shaft 45 .................... 33
Transfer box rear drive flange to drive shaft 45 ..................... 33
Transfer box to gearbox extension case 45 .......................... 33
NOTE: The following torque values are for screws and bolts not specified in the previous table.
METRIC Nm lbf ft
M5 6 ........................................................................... 5
M6 9 ........................................................................... 7
M8 25 ........................................................................... 18
M10 45 ......................................................................... 33
M12 90 ......................................................................... 65
M14 105 ......................................................................... 75
M16 180 ......................................................................... 130
UNC / UNF
1/4 9 ........................................................................... 7
5/16 25 ......................................................................... 18
3/8 40 ........................................................................... 30
7/16 80 ......................................................................... 60
1/2 90 ........................................................................... 65
5/8 135 ........................................................................... 100
AUTOMATIC GEARBOX
1
DESCRIPTION
The automatic transmission is specially tailored version of the ZF 4HP22, used by many manufacturers of high
performance vehicles.
A three element torque converter delivers the power to a four speed epicyclic transmission. First, second and third
gears are reduction ratios but fourth is an overdrive gear for high speed cruising. A direct drive clutch, integral with
the torque converter operates to engage fourth gear.
The gear selector has seven positions as follows:
P = Park provides a mechanical lock on the output shaft.
R = Reverse gear.
N = Neutral.
D = Provides a 1st gear start and automatic shifts 1-2-3-4-3-2-1.
3 = Provides a 1st gear start and automatic shifts 1-2-3-2-1.
2 = Provides a 1st gear start and automatic shifts 1-2-1 or 3-2-1.
1 = Provides a 1st gear start with no up shifts, or 3-2-1.
All automatic shifts are automatically controlled by the valve block and an hydraulic governor driven by the output
shaft.
44
AUTOMATIC GEARBOX
2
Power flow
1st gear D selected
With D selected 1st gear engaged, clutches 4 and 11 are operative. The front planet gear carrier of gear set 9 is
locked against the housing through freewheel 15 when the engine is pulling but freewheels when the vehicle is
coasting. Epicyclic gear set 10 rotates as a solid unit with the front planet gear carrier. In selector position 1 with
1st gear engaged, clutch 8 operates to prevent the loss of drive on the overrun through freewheel 15, to provide
engine braking.
2nd gear D selected
Clutches 4, 6, 7 and 11 are engaged. Freewheel 15 overruns, the hollow shaft with the sun wheel of epicyclic gear
set 9 is locked. Epicyclic gear set 10 also rotates as a solid unit.
AUTOMATIC GEARBOX
3
3rd gear D selected
Clutches 4, 5, 7 and 11 are engaged. Freewheel 15 and 16 are overrun. Epicyclic gear set 9 and 10 rotate as a
solid unit at a ratio of 1:1.
4th gear D selected
Clutches 4, 5, 7 and 12 are engaged. Freewheel 14, 15 and 16 are overrun. Epicyclic gear set 9 rotates as a solid
unit. The hollow shaft with the sun wheel of epicyclic gear set 10 is locked.
Above a predetermined road speed, clutch 2 locks the gearbox power input direct to the engine, by-passing the
torque converter.
44
AUTOMATIC GEARBOX
4
Reverse gear
Clutches 5, 8 and 11 are engaged. Since the front planet gear carrier of epicyclic gear set 9 is locked, the direction
of output-shaft rotation is reversed. Epicyclic gear set 10 also rotates as a solid block.
AUTOMATIC GEARBOX
1
FAULT DIAGNOSIS
ZF AUTOMATIC GEARBOX
Before referring to fault symptoms, carry out initial
static checks first:
INITIAL STATIC CHECKS
Check start positions P & N only ........................................................
Reverse lights R only ..................................................................
Gear engagements N-D,N-3,N-2,N-1,N-R ..........................................................
Full throttle Engine switched off, check full travel at engine and at .......................................................................
pedal.
Oil level N selected, engine running at normal running ............................................................................
temperature.
Pressure test
2000 rev/min 10 0.3 bar .................................................................... 150 5 lbf/in
2
Idle pressure at 665 to 735 rev/min. 6.9 0.3 bar ................................. 100 5 lbf/in
2
To fit pressure gauge
Service tools: See Service tools, Automatic
Gearbox
Pressure gauge 0 to 20 bar, 0 to 300 lbf/in
2
.
Flexible hose adaptor.
1. Site vehicle on a ramp [hoist].
2. From under gearbox, remove socket head plug
(located 10cm, 4 in from oil pipe). Fit hose
adaptor LST502-1.
3. Fit hose to adaptor.
4. Fit gauge 18G502Ato hose and route into
vehicle, ensuring hose is clear of rotating parts
and exhaust pipes.
5. Carry out road test. See Road Test Procedure
6. Remove pressure gauge
44
AUTOMATIC GEARBOX
2
FAULT DIAGNOSIS
ROAD TEST PROCEDURE
Follow the procedure given commencing each test,
from a standing start, on a level road, in good weather
conditions.
ROADTEST 1 = CHECKS 1-2-3-4-5-6-7-8
D SELECTED KICKDOWN START FROM REST
CHECK 1
Check for clutch squeal and slip. Check pressure is
150lbf/in
2
CHECK 2
Check 1st to 2nd upshift speed and quality. Pressure
should fall to 120 lbf/in
2
.
CHECK 3
Check 2nd to 3rd upshift speed and quality. Pressure
should fall to 100 lbf/in
2
CHECK 4
Release throttle to allow simultaneous engagement
4th + DDC. Check shift quality and engine rpm drop of
approximately 500 rpm.
CHECK 5
To proceed to Check 5, release throttle and check
drop out speed of direct drive clutch to 4th.
CHECK 6
Check down shift speed and quality 4th to 3rd.
NOTE: This shift is usually very smooth
and difficult to detect.
CHECK 7
Check downshift speed and quality 3rd to 2nd.
CHECK 8
Check downshift speed and quality 2nd to 1st. Also
difficult to detect.
ROADTEST 2 = CHECKS 9-10-11
D SELECTED FROM REST
FULL THROTTLE START
CHECK 9
Check 1st to 2nd upshift speed and quality.
CHECK 10
Check 2nd to 3rd upshift speed and quality.
CHECK 11
Check 3rd, 4th and direct drive clutch upshift speed
and quality.
NOTE: 4th and the direct drive clutch
engage simultaneously.
AUTOMATIC GEARBOX
3
FAULT DIAGNOSIS
ROADTEST 3 = CHECKS
12-13-14-15-16-17-18-19-20-21-22-23
D SELECTED FROM REST
LIGHT THROTTLE START
CHECK 12
Check 1st to 2nd upshift speed and quality.
CHECK 13
Check 2nd to 3rd upshift speed and quality.
CHECK 14
Check 3rd to 4th upshift speed and quality.
NOTE: This shift is usually very difficult to
detect but can be confirmed by a 200 rpm
drop in engine speed.
CHECK 15
Check speed and quality of shift into direct drive
clutch, confirmed by 300 rpm drop in engine speed.
NOTE: An intermediate throttle position
engagement of 4th and the direct drive
clutch, which is indicated by a fall of 500
rpm in engine speed.
CHECK 16
At approximately 88 kph, 55 mph depress throttle to
kickdown - gearbox should change down to 2nd -
release throttle to re-engage 4th direct drive clutch
continue to accelerate gently.
CHECK 17
At approximately 128 kph, 80 mph depress throttle to
kickdown - gearbox should change down to 3rd -
release throttle to re-engage 4th direct drive clutch
and continue to accelerate gently.
CHECK 18
At approximately 138 kph, 85 mph select 3rd, gearbox
should change immediately down to 3rd. Release
throttle.
CHECK 19
De-accelerate to approximately 47 kph, 30 mph
depress throttle to kickdown - geabox should
downshift to 1st gear, continue accelerating at full
throttle until 3rd gear is attained. To do this you will
have repeated check 2 of Test 1.
CHECK 20
At 128 kph, 80 mph select 2nd no downshift should
occur. Release throttle.
CHECK 21
At 104 kph, 65 mph an automatic downshift into 2nd
gear should occur. Continue to de-accelerate.
CHECK 22
At 88 kph, 55 mph select 1st. No downshift should
occur. Continue to de-accelerate.
CHECK 23
With 1 selected 2nd gear engaged, continue to
de-accelerate and at 45 kph, 28 mph the box should
automatically downshift to 1st gear after which no
upshifts will occur in this selector position.
END OF ROADTEST
44
AUTOMATIC GEARBOX
4
FAULT DIAGNOSIS
AUTOMATIC GEARBOX ASSEMBLY
1. Gearbox assembly
2. Inhibitor switch assembly
3. Control unit assembly
4. Filter and sump assembly
AUTOMATIC GEARBOX
5
FAULT DIAGNOSIS
1. Torque converter housing assembly
2. Gearbox pump and casing assembly
3. Governor and adaptor housing assembly
44
AUTOMATIC GEARBOX
6
FAULT DIAGNOSIS
1. A Clutch assembly
2. B Clutch assembly
AUTOMATIC GEARBOX
7
FAULT DIAGNOSIS
1. C,C and D Clutch assembly
44
AUTOMATIC GEARBOX
8
FAULT DIAGNOSIS
1. Freewheel and fourth gear assembly
AUTOMATIC GEARBOX
9
FAULT DIAGNOSIS
1. E and F Clutch assembly
44
AUTOMATIC GEARBOX
10
FAULT DIAGNOSIS
FAULT SYMPTOMS
SYMPTOM 1 - Intermittent drive and high pitched
noise
FAULT - Low fluid level or restricted filter
SYMPTOM 2 - No drive in reverse
Select D
No drive
FAULT - Continue with Symptom 3
Drives forward
FAULT - Reverse gear interlock valve seized
Select 1
No engine braking
FAULT - Clutch brake 3
SYMPTOM 3 - No drive from rest with D selected
Select 1
Vehicle drives
FAULT - No 2 freewheel
No drive
Carry out main line pressure check
Normal pressure
FAULT - Clutch A
No pressure
FAULT - Blocked filter or pump failure
Low pressure
FAULT - Restricted filter or sticking primary
regulator
SYMPTOM 4 - Slip in all forward gears
No pressure
FAULT - Blocked filter or pump failure
Low pressure
FAULT - Restricted filter or sticking primary
regulator
Normal pressure
FAULT - Clutch A
SYMPTOM 5 - Harsh engagement N to D
Check engine idle speed
High pressure
FAULT - Primary regulator stuck
Normal pressure
FAULT - Clutch A or damper for clutchA
SYMPTOM 6 - Fierce shift or flare 1st to 2nd shift
Check engine idle speed
Carry out mainline pressure check
High pressure
FAULT - Continue with symptom 5
Normal pressure
FAULT - Modulator valve or dampers for clutch
brake CB1 and/or clutch brake CB2
FAULT - Clutch brake CB1 and/or clutch brake
CB2
SYMPTOM 7 - Fierce shift or flare 2nd to 3rd
Carry out mainline pressure check
High pressure
FAULT - Continue with symptom 5
Normal pressure
FAULT - Modulator valve or clutch B damper
FAULT - Clutch B
SYMPTOM 8 - No 3rd gear
FAULT - 2-3 shift valve
FAULT - Clutch B
SYMPTOM 9 - No 4th gear D selected
FAULT - 4th to 3rd downshift valve stuck or 3rd
to 4th upshift valve stuck
AUTOMATIC GEARBOX
11
FAULT DIAGNOSIS
SYMPTOM 10 - None or harsh engagement of
direct drive clutch
NOTE: The direct drive clutch will only
engage if 4th gear is engaged at 40 to 45
mph.
Carry out road test pressure check with gauge
connected to torque converter.
Normal pressure
FAULT - Failed direct drive clutch
Pressures correct but remains high
FAULTS POSSIBLE -
Direct drive clutch and torque converter control
valve stuck
Hysteresis valve stuck
Direct drive clutch control valve stuck
SYMPTOM 11 - Direct drive clutch shift point
incorrect or at low speed
NOTE: Direct drive clutch engagement at
low speed will cause vibration in the
torque converter
Carry out mainline and torque converter pressure
check
Normal pressure
FAULT - Governor valve sticking
Low or incorrect pressure
FAULTS POSSIBLE -
Direct drive clutch and torque converter control
valve sticking.
Hysteresis valve stuck.
Direct drive clutch control valve stuck.
SYMPTOM 12 - Drives in D but immediately
upshifts to 3rd
FAULT - 2nd to 3rd shift valve stuck.
SYMPTOM 13 - With D selected vehicle starts in
2nd
FAULTS POSSIBLE -
1st and 2nd shift valve stuck.
Governor sleeve sticking.
SYMPTOM 14 - With D selected vehicle starts in
3rd
FAULTS POSSIBLE -
1st to 2nd and 2nd to 3rd shift valves stuck.
Governor sleeve sticking.
SYMPTOM 15 - No kickdown 4th to 3rd
FAULT - 4th to 3rd kickdown valve stuck.
SYMPTOM 16 - Upshifts/downshifts and kickdown
shifts at incorrect road speeds
Check throttle kickdown cable adjustment
Normal pressure
FAULT - Governor valve sticking
Incorrect pressure
FAULTS POSSIBLE -
Incorrect throttle valve adjustment
Primary regulator sticking
SYMPTOM 17 - No upshifts at light throttle
FAULTS POSSIBLE
Governor valve sticking
Shift valves sticking
SYMPTOM 18 - No engine braking 3 selected 3rd
gear
FAULT - Clutch C
SYMPTOM 19 - Delayed or no downshift occurs
when making a manual selection from 3 to 2
FAULTS POSSIBLE -
2nd and 3rd upshift valve sticking.
Governor valve sticking.
2 Position interlock valve sticking.
SYMPTOM 20 - At speeds below 28 mph when
making a manual selection from 2 to 1,
downshift is delayed or does not occur
FAULTS POSSIBLE -
Governor sticking.
1st to 2nd shift valve sticking.
1 Position interlock valve sticking.
SYMPTOM 21 - 1 Selected 1st gear no engine
braking
SYMPTOM 22 - 2 Selected 2nd gear no engine
braking
SYMPTOM 23 - Vehicle drives forward in N
FAULT - Clutch A stuck
AUTOMATIC GEARBOX
1
ADJUSTMENT
KICKDOWN CABLE ADJUSTMENT
1. Release and remove kick-down cable clevis pin.
2. Loosen locknut and release kickdown cable from
abutment bracket.
3. Release outer cable sleeve from clip on rear of
LH cylinder head.
4. Holding cable as straight as possible, extend
inner cable to first detent.
5. With inner cable extended, check dimension A
between end of threads and crimped sleeve.
Dimension A = 42 mm 3 mm, 1.65 0.10 in.
6. Connect cable to abutment bracket and fit
locknut.
7. Secure outer cable sleeve to clip on rear of LH
cylinder head.
8. Connect kick-down cable to throttle lever and
secure with clevis pin.
9. Adjust outer cable until crimped sleeve is
dimension B from end of outer cable.
Dimension B = 1 mm, 0.04 in.
10. Tighten locknut.
AUTOMATIC GEARBOX
1
REPAIR
KICKDOWN CABLE
Remove
1. Site vehicle on a four post ramp [hoist].
2. Select neutral N.
4. Remove clevis pin and release kickdown cable
at throttle linkage.
5. Release outer cable locknut.
6. Disconnect cable from abutmet bracket.
7. Release cable from retaining clip at bracket
attached to cylinder head.
8. Feed cable through to underside of vehicle.
10. Remove gearbox fluid pan See Fluid pan
gasket and screen.
11. Remove 13 bolts securing control unit assembly
to gearbox.
12. Rotate accelerator cam and release nipple of
kickdown inner cable from cam.
13. Using special tool LRT-44-004, compress cable
tangs and remove cable from gearbox.
14. If cable is to be refitted, remove O ring seal and
clean cable assembly.
Refit
15. Fit NEW O ring seal to cable and lubricate seal.
16. Fit cable to gearbox casing ensuring it is
correctly seated.
17. Spring load cam by turning once and fit inner
cable nipple into cam seat.
NOTE: When a new cable is fitted, to help
locate nipple to cam, introduce a curve
into the cable. DO NOT bend or kink cable.
18. Ensuring cable nipple remains engaged, feed
free end of cable assembly into engine
compartment.
19. Locate control unit assembly to gearbox and
loosely fit 13 bolts. Ensure selector shaft locates
into gear shift fork.
44
AUTOMATIC GEARBOX
2
REPAIR
20. Locate selector linkage setting gauge
LRT-44-002in position and gently press control
unit forwards as shown. Tighten bolts to 8 Nm, 6
lbf ft.
21. Remove setting gauge.
22. Refit gearbox fluid pan See Fluid pan gasket
and screen.
23. Lower vehicle on ramp [hoist].
24. Adjust kickdown cable See Adjustment,
Kickdown cable adjustment.
26. Refill gearbox oil using correct grade of oil See
Information, Recommended Lubricants and
Fluids.
INHIBITOR SWITCH
Remove
2. Disconnect battery negative lead. Raise vehicle.
3. Disconnect inhibitor switch multiplug.
4. Remove inhibitor switch retaining plate.
5. Remove inhibitor switch.
6. Remove O ring seal.
7. Clean inhibitor switch.
Refit
8. Clean mating face on casing.
9. Fit and lubricate NEW O ring seal to switch.
10. Fit switch to casing.
11. Secure with retaining plate and bolt.
12. Connect multiplug to harness.
13. Reconnect battery and remove vehicle from
ramp [hoist].
AUTOMATIC GEARBOX
3
REPAIR
FLUID PAN GASKET AND SCREEN
Service repair no - 44.24.05 - Fluid pan gasket
Service repair no - 44.24.07 - Fluid screen
Remove
3. Raise vehicle.
4. Drain fluid and refit plug with new seal. Tighten
to 43 Nm, 32 lbf ft.
5. Remove catalytic converter assembly See
EMISSION CONTROL, Repair, Front
pipe/catalytic converter.
6. Release fuel pipes from retaining clip secured by
top RH chassis crossmember bolt.
9. Disconnect dipstick tube from fluid pan. Loosen
securing bolt at bell housing and move tube
aside.
10. Remove clamps securing fluid pan. Note their
locations for refit and withdraw pan.
11. Remove gasket and clean gasket mating faces.
12. Remove securing screws and detach oil screen
and suction pipe, taking care to retain suction
pipe spacer, discard O ring seal.
13. Detach suction pipe from fluid screen, discard
O ring seal.
Refit
14. Clean fluid screen and blow out with airline.
15. Clean suction pipe.
16. Fit new O ring seals to fluid screen using light
grease to aid assembly.
17. Fit fluid screen and suction pipe with spacer and
secure with bolts. Tighten to 8 Nm, 6 lbf ft.
18. Refit fluid pan using a NEW gasket. Tighten to 8
Nm, 6 lbf ft.
19. Connect dipstick tube to fluid pan, tighten bolt at
bell housing. Filler tube union nut Tighten to 70
Nm, 52 lbf ft.
20. Position both exhaust heat shields and refit
chassis cross-member. Secure fuel pipes to
retaining clip.
21. Refit catalytic converter assembly See
EMISSION CONTROL, Repair, Front
pipe/catalytic converter.
22. Connect battery.
23. Refill transmission using correct grade of fluid
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids.
24. Apply parking brake and with selector at P, run
engine at idle.
25. Apply footbrake, from P, move selector to
position 1 and back to N. Check fluid level, this
must be between the level marks. Top-up as
necessary.
44
AUTOMATIC GEARBOX
4
REPAIR
TORQUE CONVERTER
Remove
1. Remove gearbox and transfer box assembly,
See Gearbox and transfer box assembly
2. Place gearbox on bench. Remove torque
converter using torque converter handle
LRT-44-010, taking care not to damage torque
converter/oil pump housing oil seal.
Refit
3. Fit NEW torque converter using torque converter
handles LRT-44-010. Check dimension from
converter fixing boss to converter housing face is
50 mm, 1.968 in. This shows converter is
correctly seated in housing.
4. Refit gearbox and transfer box assembly. See
Gearbox and transfer box assembly
PUMP AND MAIN HOUSING
Service repair no - 44.20.11 - Intermediate plate
gasket
Service repair no - 44.32.01 - Pump assembly
Service repair no - 44.32.07 - Pump oil seal
Remove
1. Remove gearbox and transfer box assembly,
See Gearbox and transfer box assembly
2. Place gearbox on bench. Remove torque
converter using torque converter handles
LRT-44-010, taking care not to damage torque
converter/oil pump housing oil seal.
3. Remove 12 bolts (inner ring of bolts).
4. Remove bell housing and pump assembly,
discard gasket.
5. Remove 8 bolts from rear of pump.
AUTOMATIC GEARBOX
5
REPAIR
6. Screw in 2 bolts, diagonally opposite each other.
Tap lightly using a soft headed mallet to remove
pump assembly from intermediate plate.
7. Remove shaft sealing ring and O ring from
pump housing and discard.
Refit
8. Using oil seal replacer LRT-44-001 fit shaft seal
ring into pump housing.
9. Fit O ring onto circumference of pump housing.
10. Align dowel with hole in intermediate plate and
press pump housing home.
11. Fit pump housing to intermediate plate, tighten
12. Place bell housing and intermediate plate
assembly on bench, front face up. Using oil
pump rotation sleeve LRT-44-003(LST111),
check that pump gears rotate freely.
13. Before fitting intermediate plate and bell housing
assembly, check that thrust washer and axial
cage are seated on clutch housing.
14. Place NEW gasket and selective disc washer
onto bell housing and intermediate plate
assembly using Petroleum Jelly.
15. Fit bell housing and intermediate plate assembly
to gearcase. Tighten bolts to 46 Nm, 34 lbf ft.
16. Place end float gauge LRT-44-003 onto pump
housing and check that axial play is between 0.2
- 0.4 mm, 0.008 - 0.016 in. Replace existing
washer, situated at rear of intermediate plate,
with a washer selected to give required end float.
17. Refit torque converter into housing using torque
converter handles LRT-44-010. Check that
dimension from converter fixing bolt boss to
converter housing face is 50 mm, 1.968 in to
comfirm that converter is properly seated in
housing.
18. Refit gearbox/transfer box assembly. See
Gearbox and transfer box assembly
44
AUTOMATIC GEARBOX
6
REPAIR
GEARBOX AND TRANSFER BOX ASSEMBLY
Remove
1. Position vehicle on 4-post ramp.
2. Select LOW range gear and leave vehicle in
neutral.
4. Drain gearbox oil. See SECTION 10,
5. Drain transfer gearbox oil. See SECTION 10,
BODY, Repair, centre console
8. Remove hi-low selector housing cover from
tunnel.
9. Working through hi-low gear lever aperture,
disconnect inhibitor/reverse light switch
multiplug.
10. Remove 2 cable ties securing gearbox and
transfer box breather pipes to harness.
11. Remove 3 trim studs securing hand brake gaiter.
12. Release hand brake gaiter to access cable
linkage.
13. Remove split pin and clevis pin securing hand
brake cable to lever.
14. Remove 2 screws securing fan cowl to upper
retaining brackets.
15. Release 2 clips securing upper fan cowl.
16. Remove upper fan cowl.
AUTOMATIC GEARBOX
7
REPAIR
17. Remove kick-down cable clevis pin.
18. Release kick-down outer cable lock nut.
19. Release kick-down outer cable from abutment
bracket.
20. Release kick-down outer cable from clip on rear
of LH cylinder head.
21. Remove bolt securing 2 breather pipe P clips to
rear of RH cylinder head.
22. Remove 6 bell housing to engine bolts.
23. Raise vehicle.
24. Remove exhaust front pipe. See EMISSION
converter
pipe.
26. Release intermediate pipe from tail pipe and
remove from mounting.
28. With assistance, and using a body jack between
29. Remove crossmember.
31. Remove bolt securing LH and RH catalyst heat
shields to chassis.
32. Remove catalyst heat shields.
44
AUTOMATIC GEARBOX
8
REPAIR
front propeller shaft to transfer box flanges.
rear propeller shaft to brake drum flanges.
35. Remove 4 nuts securing front propeller shaft to
transfer box flange.
NOTE: Rotate propeller shaft to gain
access to all fixing.
36. Release propeller shaft from transfer box flange
bolts and tie aside.
37. Remove 4 nuts securing rear propeller shaft to
brake drum flange.
access to all fixing.
38. Release propeller shaft from brake drum bolts
and tie aside.
39. Remove 7 bolts securing bell housing closing
40. Remove 3 bolts securing bell housing access
41. Mark relationship between converter and drive
plate.
42. Rotate crankshaft to access drive plate to
converter fixing.
43. Remove 4 bolts securing drive plate to
converter.
44. Fit suitable piece of wood through bell housing
access hole to retain converter.
AUTOMATIC GEARBOX
9
REPAIR
45. Remove clamp bolt securing gearbox cooler
pipes to engine sump bracket.
46. Loosen gearbox cooler pipe unions and
disconnect from gearbox.
47. Remove and discard O rings from pipes.
48. Tie cooler pipes aside.
49. Loosen gearbox filler tube union and remove
from fluid pan.
50. Remove and discard O ring from union.
51. Remove split pin from selector cable yoke and
collect washer.
52. Release yoke from lever.
53. Remove bolt securing selector outer cable clamp
to transfer box LH mounting.
54. Remove nut securing oxygen sensor multiplug
bracket from transfer box earth bolt and collect
bracket.
55. Remove nut securing earth strap to transfer box
and release strap.
44
AUTOMATIC GEARBOX
10
REPAIR
56. Release hand brake outer cable from body.
57. Remove bolt securing earth lead to RH side of
transfer box.
58. Fit transmission cradle LRT-99-008A to
transmission jack.
59. Fit and tighten bolts securing cradle to jack.
60. Remove 2 lower bolts securing transfer box rear
cover.
61. Collect hand brake cable heat shield.
62. Raise jack and align cradle to transmission.
63. Refit previously removed transfer box rear cover
bolts to secure cradle.
64. Remove 2 nuts and bolts securing heat shield to
transfer box LH mounting bracket.
65. Remove heat shield.
66. Remove 3 nuts and bolts securing transfer box
LH mounting bracket to chassis.
67. Release earth lead from fixing.
68. Remove nut securing transfer box RH mounting.
69. Remove 3 nuts and bolts securing transfer box
RH mounting bracket to chassis.
70. Remove transfer box RH mounting bracket and
collect flexible mount heat shield.
71. Lower transmission on jack to access harness
connectors.
AUTOMATIC GEARBOX
11
REPAIR
72. Disconnect the following multiplugs/connectors
from transfer box:
Speed transducer
Parking solenoid
Neutral detection switch
Differential lock
Temperature sensor switch
73. Remove 2 cable ties securing harness to
transfer box.
74. Position jack to support engine sump.
rubber pad to protect sump.
75. Remove 2 remaining bell housing to engine
bolts.
76. With assistance, lower transmission and engine
jacks until hi-low selector lever is clear of
transmission tunnel aperture.
77. Separate transmission from engine and lower on
jack.
78. Remove transmission assembly from beneath
ramp.
79. Position lifting eyes to transmission and secure
with bolts.
80. Fit lifting chains to eyes and connect.
81. Position lifting hoist and connect lifting chains.
82. Raise hoist until chains are taught.
83. Remove bolts securing cradle to transfer box.
84. Raise transmission from cradle.
85. Refit transfer box rear cover plate bolts.
86. Lower transmission assembly onto work bench.
87. Disconnect lifting chains from eyes.
88. Remove bolts securing eyes to transmission and
remove eyes.
Refit
89. Position lifting eyes to transmission and secure
with bolts.
90. Connect lifting chains to eyes.
91. Raise transmission assembly from bench and
position above transmission cradle.
92. Remove 2 transfer box rear cover plate bolts.
93. Lower transmission onto cradle, align to transfer
box rear cover plate and secure with previously
removed bolts.
94. Lower hoist and disconnect lifting chains from
eyes.
95. Remove chains from hoist.
96. Remove bolts securing lifting eyes to
transmission and remove eyes.
97. Position transmission assembly beneath vehicle.
98. Clean engine to gearbox mating faces.
99. Clean engine to gearbox dowels and dowel
holes.
100. With assistance, raise transmission on jack and
position to engine dowels.
101. Fit 2 lower bell housing to engine bolts and
102. With assistance, raise engine and transmission
jacks to position transmission assembly.
NOTE: Do not fully raise transmission at
this stage as access is required for
connection of connectors to transfer box.
103. Remove engine jack from beneath vehicle.
104. Secure harness to transfer box with cable ties.
105. Connect multiplugs/connectors to transfer box.
106. Raise transmission and align to mounting
locations.
107. Fit transfer box RH flexible mounting heat shield
and mounting bracket.
108. Align RH mounting to chassis and secure with
nuts and bolts.
109. Fit and tighten nut securing RH mounting.
110. Align LH mounting to chassis and secure with
nuts and bolts.
NOTE: Position earth lead to mounting
fixing.
111. Position heat shield to LH mounting bracket and
secure with fixings.
112. Remove bolts securing transmission cradle to
transfer box.
113. Lower transmission jack and remove from
beneath ramp.
114. Fit and tighten transfer box rear cover bolts.
NOTE: Position heat shield to cover plate
fixing.
115. Position earth lead to RH side of transfer box
and secure with bolt.
116. Feed hand brake outer cable through body.
NOTE: Apply a soap solution to aid fitment
of cable to body.
117. Position earth strap to transfer box stud and
secure with nut.
118. Fit oxygen sensor multiplug bracket to transfer
box earth bolt and secure with nut.
44
AUTOMATIC GEARBOX
12
REPAIR
119. Position selector outer cable clamp to transfer
box LH mounting and secure with bolt.
120. Position selector cable yoke to lever, fit washer
and secure with split pin.
121. Remove plug from transmission filler tube union.
122. Lubricate new O ring with gearbox oil and fit to
filler tube.
123. Fit filler tube to gearbox and tighten union.
124. Release cooler pipes and remove plugs from
connections.
125. Lubricate new O rings with gearbox oil and fit to
pipes.
126. Position cooler pipes to gearbox and tighten
unions.
127. Position cooler pipes to engine sump bracket, fit
clamp and secure with bolt.
128. Remove piece of wood from bell housing access
hole.
129. Align converter to drive plate.
130. Fit bolts securing converter to drive plate and
NOTE: Rotate crankshaft during the above
procedure.
131. Fit bell housing access plate and secure with
bolts tightened to 9 Nm, 7 lbf ft. .
132. Clean bell housing cover plate and mating face.
133. Fit plate and secure with bolts tightened to 9
Nm, 7 lbf ft.
134. Clean rear propeller shaft to brake drum mating
faces.
135. Release rear propeller shaft, align flange
markings and connect to studs.
136. Fit nuts securing rear propeller shaft to brake
drum and tighten to 47 Nm, 35 lbf ft.
access to all fixings.
137. Clean front propeller shaft to transfer box mating
faces.
138. Release front propeller shaft, align flange
markings and connect to studs.
139. Fit nuts securing front propeller shaft to transfer
box and tighten to 47 Nm, 35 lbf ft.
access to all fixings.
enable fitment of crossmember.
141. Fit crossmember and align fixings.
143. Fit nuts and bolts securing chassis
crossmember, but do not tighten.
144. Fit LH and RH catalyst heat shields to chassis, fit
bolts but do not tighten.
145. Align LH and RH catalyst heat shields to chassis
crossmember fixings and tighten all fixings.
146. Clean intermediate to tail pipe flange.
147. Fit intermediate pipe to mounting rubber,
connect to tail pipe and secure with nuts.
148. Fit exhaust front pipe. See EMISSION
converter; Refit
149. Lower vehicle.
150. Fit bolts securing bell housing to engine and
tighten to 46 Nm .
NOTE: Align harness brackets to 2
uppermost bell housing retaining bolts.
151. Align breather pipe P clips to rear of RH
cylinder head and secure with bolt.
152. Secure kick-down outer cable to clip on rear of
LH cylinder head.
153. Secure kick-down outer cable to abutment
bracket.
154. Secure kick-down outer cable lock nut.
155. Align kick-down cable to linkage and secure
clevis pin.
156. Adjust kick-down cable. See Adjustment,
kickdown cable adjustment
157. Fit upper fan cowl and secure with clips.
158. Align fan cowl to upper retaining brackets and
secure with screws.
159. Align hand brake cable to lever, fit clevis pin and
secure with split pin.
160. Position hand brake gaiter and secure with trim
studs.
161. Secure gearbox and transfer box breather pipes
to harness with cable ties.
162. Connect inhibitor/reverse light switch multiplug.
163. Fit hi-low selector housing cover to tunnel.
164. Fit carpet to transmission tunnel.
Repair, centre console
166. Refill transfer gearbox oil. See SECTION 10,
167. Refill gearbox oil. See SECTION 10,
169. Select Hi range gear and park.
170. Remove vehicle from ramp.
AUTOMATIC GEARBOX
1
TORQUE VALUES
Nm lbf ft
Coupling shaft to mainshaft 42* .............................................. 30*
Filler tube to sump 68 ............................................................ 50
Gear change lever to gearbox 25 .......................................... 18
Cooler pipe adaptor to gearbox 42 ........................................ 30
Securing screws - clutch F 10 ............................................... 7
Securing screw - parking pawl 10 ......................................... 7
Securing screws - pump 10 ................................................... 7
Intermediate plate plugs (M20) 50 ........................................ 35
Intermediate plate plugs (M14) 40 ........................................ 30
Bell housing mounting bolts 46 ............................................. 34
Governor mounting screws 10 .............................................. 7
Extension housing bolts 23 ................................................... 17
Control unit mounting bolts 8 .............................................. 6
Draib plug - fluid pan 10 ........................................................ 7
Mounting screws for sump 8 ............................................... 6
Drive plate to converter 39* .................................................... 29*
Gearbox to engine 42 ............................................................ 31
Strut (threaded end) 42 ......................................................... 31
Bottom cover to converter housing 9 .................................. 7
Cover - converter housing 9 ................................................ 7
Drive plates to crankshaft adaptor 40* ................................... 30*
Adaptor to crankshaft 84 ....................................................... 62
NOTE: * These bolts MUST have threads coated with Loctite 270 prior to assembly.
Torque values below are for all screws and bolts used except for those that are specified otherwise.
METRIC Nm lbf ft
M5 6 ........................................................................... 5
M6 9 ........................................................................... 7
M8 25 ........................................................................... 18
M10 45 ......................................................................... 33
M12 90 ......................................................................... 65
M14 105 ......................................................................... 75
M16 180 ......................................................................... 130
UNC / UNF Nm lbf ft
1/4 9 ........................................................................... 7
5/16 24 ......................................................................... 18
3/8 39 ........................................................................... 28
7/16 78 ......................................................................... 58
1/2 90 ........................................................................... 65
5/8 136 ........................................................................... 100
44
AUTOMATIC GEARBOX
2
ZF GEARBOX DATA
Axial end float 0.2 - 0.4 mm. ................................................................... 0.008 - 0.016 in
From torque converter boss to torque converter
housing face 50 mm ..................................................................... 1.968 in
Freewheel cage assembly to ring gear;
minimum clearance 0.1 mm .......................................................... 0.004 in
Output shaft dimension above cylinder F assembly 10.00 mm ......... 0.394 in
A cylinder maximum protrusion above gearbox front
face 8.5 mm .................................................................................. 0.335 in
PROPELLER SHAFTS
1
PROPELLER SHAFT ALIGNMENT
Description
The front and rear propeller shafts have non-constant
velocity Hooks type universal joints, with needle roller
bearings. The bearing cups are pre-packed with
lubricant on assembly and a grease nipple is fitted for
servicing as specified, in maintenance section.
Both shafts have Rilsan coated sliding splines to
accommodate the variation in distance between the
axles and transmission. The splines are pre-packed
with lubricant and sealed.
The front shaft is a solid bar, which is shorter than the
rear, with the joints Phased at each end, A and B
mis-aligned. The phasing is necessary on the front
shaft only to allow for greater variation in angular
changes.
The rear shaft is a tube fitted with a conventional joint
at gearbox end and the sliding joint sealed with a
rubber gaiter.
Propeller shaft
1. Flanged yoke
2. Grease nipple
3. Journal spider
4. Needle roller bearing
5. Circlip
6. Splined shaft
7. Rubber gaiter (dust cap)
8. Splined shaft
PROPELLER SHAFTS
1
FAULT DIAGNOSIS
VIBRATION HARSHNESS
1. Check that the propeller shaft universal joints
and sliding splines are not siezed or worn and
that the shafts are correctly aligned.
NOTE: In the event that both shafts are
satisfactory, but the vibration/harshness is
still present, the transfer box operation
and balance of the road wheels should be
checked.
For transfer gearbox operation. See TRANSFER
GEARBOX, Description and operation, LT230Q
Transfer Gearbox
For balance of road wheels. See WHEELS AND
TYRES, Repair, Wheel Balancing
PROPELLER SHAFTS
1
REPAIR
PROPELLER SHAFTS
Service repair no - 47.15.02 - Front
Service repair no - 47.15.03 - Rear
Remove
1. Place vehicle over pit or on a ramp [hoist].
2. Remove nuts from each end of propeller shaft.
Remove shaft.
3. Scribe alignment marks on flanges at both ends
of propeller shaft to ensure correct refitting.
Overhaul
Service repair no - 47.15.11 - Front
Service repair no - 47.15.12 - Rear
4. Thoroughly examine universal joint for signs of
damage or wear. Replace if necessary.
5. Clean universal joint bearing cups and circlips.
CAUTION: To ensure correct assembly
and reduce possibility of imbalance.
Before removing propeller shaft joint. Mark
position of spider pin lubricator relative to journal
yoke ears.
6. Remove circlips, and grease nipple.
7. Tap yokes to eject bearing cups.
8. Remove bearing cups and spider.
9. Repeat instructions 4 to 7 for opposite end of
propeller shaft if necessary.
10. Clean yokes and bearing cup locations.
Assemble
11. Remove bearing cups from new spider.
12. Check all needle rollers are present and
positioned in bearing cups.
13. Ensure bearing cups are one-third full of
lubricant. See LUBRICANTS, FLUIDS AND
Lubricants and Fluids
14. Enter new spider with seals into yokes of sliding
member flange.
15. Partially insert one bearing cup into flange yoke
and enter spider trunnion into bearing cup.
16. Insert opposite bearing cup into flange yoke.
17. Press both cups into place.
47
PROPELLER SHAFTS
2
REPAIR
18. Press each cup into its respective yoke up to
lower land of circlip grooves. Damage may be
caused to cups and seals if cups pass this point.
19. Fit circlips and check no end float exists.
20. Engage spider in yokes of sliding member. Fit
bearing cups and circlips as described in
instructions 14 to 19.
21. Fit grease nipples to spider and sliding member.
22. Apply instructions 14 to 19 to opposite end of
propeller shaft.
23. Fit grease nipple and lubricate.
Refit
24. Fit propeller shafts to vehicle and tighten nuts to
47Nm, 35 lbf ft
Refit propeller shaft so sliding joint end of shaft
is fitted to transfer gearbox.
PROPELLER SHAFTS
1
TORQUE VALUES
Nm lbf ft
Propeller shaft flange nuts 47 ............................................... 35
REAR AXLE AND FINAL DRIVE
1
DESCRIPTION
The welded steel rear axle casing houses a separate
spiral bevel type differential unit, which is off set to the
right of the vehicle centre line. The differential unit
drives the rear wheels via the axle shafts and fully
floating hubs which are mounted on tapered roller
bearings.
Lubrication
The differential is lubricated with oil and the hub
bearings with grease. The hub bearings are fitted with
inner and outer seals. The outer seals prevent the
differential oil mixing with the hub grease and the
inner seals prevent dirt ingress into the hub.
Ventilation
Ventilation of the hub bearings is through the outer oil
seals and the differential ventilation pipe, which
terminates at a high level.
Rear axle hub
1. Axle casing
2. Ventilation pipe
3. Axle shaft
4. Wheel studs and hub
5. Wheel bearing stub axle
6. Wheel bearings (2)
7. Inner hub seal
8. Outer hub/axle shaft seal
9. Hub lock plate, thrust washer and nuts (2)
10. Brake disc
11. Sensing ring - road speed
1
FAULT DIAGNOSIS
FAULT DIAGNOSIS
Complaint - Oil leaks
An external leak of lubricant from the hub seals can
be caused by a faulty internal seal. For example, if the
seals which separate the differential from the hubs are
faulty and the vehicle is operating or parked on an
embankment, oil from the differential may flood one
hub resulting in a lack of lubrication in the differential.
When a seal is found to be leaking check the axle
ventilation system, as a blockage can cause internal
pressure to force oil past the seals.
See Description and Operationfor an illustration of
oil seal locations.
When investigating hub seal leaks, check the grease
for dilution with oil. Also check the differential oil level,
for signs of metal particles in the oil and the condition
of internal seals.
If the vehicle is driven in deep water with defective oil
seals, water may contaminate the lubricants and raise
the differential oil level, giving a false impression that
the housing has been overfilled. Do not assume that
a high oil level in the differential is due to over
filling or, that a low level is because of an external
leak.
1
REPAIR
REAR AXLE
Remove
WARNING: Remove and refit of axle
requires a further 2 persons to steady the
axle when lowering or repositioning.
1. Drain brake system.
2. Support rear of chassis.
3. Remove rear road wheels.
4. Support axle weight with hydraulic jack.
5. Disconnect shock absorbers.
6. Disconnect flexible brake hose at RH chassis
crossmember and vetilation pipe at banjo
connection on axle casing.
7. Disconnect lower links at axle.
8. Mark differential and propeller shaft flanges with
alignment marks for assembly.
9. Remove 4 nuts and bolts, lower propeller shaft
and tie to one side.
10. Disconnect pivot bracket ball joint at axle
bracket. Disconnect wheel speed sensor lead
plugs at LH side of chassis. Release sensor lead
retaining clips from chassis and A frame.
11. Release bolts and remove coil spring retaining
plates.
12. Lower axle and remove road springs.
13. Remove anti-roll bar links at axle See REAR
SUSPENSION, Repair, anti-roll [sway] bar
ball joint links
14. Remove axle assembly.
15. Transfer components to new axle.
51
2
REPAIR
Refit
16. Position axle and fit lower links. Tighten fixings
17. If applicable, fit anti-roll bar links to axle See
REAR SUSPENSION, Repair, anti-roll bar
joint links .
18. Raise axle and locate road springs.
19. Fit coil spring retaining plates and secure with
fixing bolts.
20. Secure pivot bracket ball joint to axle bracket.
Tighten fixing to 175 Nm, 130 lbf/ft.
21. Reconnect road speed sensor lead plugs and
secure leads to chassis and A frame.
22. Align propeller shaft to differential drive flange
and tighten fixings to 48 Nm, 35 lbf/ft.
23. Reconnect flexible brake hose and axle
ventilation pipe.
24. Refit shock absorbers.
25. Fit road wheels.
26. Remove rear chassis support.
brake system bleed
3
REPAIR
Rear hub components
1. Nut - sensor ring
2. Axle shaft.
3. Axle shaft joint washer.
4. Axle shaft retaining bolt - 5 off.
5. Lock nut.
6. Lock washer.
7. Hub adjusting nut.
8. Spacing washer.
9. Outer bearing.
10. Hub.
11. Inner bearing.
12. Grease seal.
13. Brake disc.
14. Disc retaining bolt - 5 off.
15. Sensor ring - engine management
REAR HUB ASSEMBLY
Remove
1. Raise rear of vehicle and support rear axle onto
axle stands. Remove appropriate road wheel.
2. Release brake hose clips and remove brake
caliper bolts. Secure caliper to one side.
WARNING: Take care not to kink brake
hose.
3. Remove 5 bolts and withdraw axle shaft.
4. Remove and discard joint washer.
5. Bend back lock washer tabs.
6. Remove locknut and lock washer. Discard lock
washer.
7. Remove hub adjusting nut.
8. Remove spacing washer.
9. Remove hub and brake disc assembly complete
with bearings.
51
4
REPAIR
Refit
10. Clean stub axle.
11. Fit hub assembly to stub axle.
12. Fit spacing washer.
13. Fit hub adjusting nut. Tighten to 50 Nm, 37 lbf/ft
ensure hub is free to rotate with no bearing play.
Back off adjusting nut 90and tighten to 10 Nm,
7 lbf/ft .
14. Fit a NEW lock washer.
15. Fit locknut. Tighten to 61 Nm, 45 lbf/ft .
16. Tab over lock washer to secure adjusting nut
and locknut.
17. Using a NEW joint washer, fit axle shaft to hub.
Tighten bolts to 65 Nm, 48 lbf/ft .
18. Fit brake caliper. Tighten bolts to 82 Nm, 60
lbf/ft . Secure brake pipes to axle casing.
19. Fit road wheel, remove axle stands and tighten
road wheel nuts to 130 Nm, 95 lbf/ft.
20. Operate footbrake to locate brake pads before
driving vehicle.
DIFFERENTIAL ASSEMBLY
Remove
1. Raise and support rear axle on axle stands.
Position drain tray and drain axle oil. Refit drain
plug.
2. Mark differential and propeller shaft flanges to
facilitate reassembly.
3. Remove 4 bolts and disconnect propeller shaft
from differential. Tie aside.
4. Remove hub drive member fixings and withdraw
axle half shafts sufficiently to disengage from
differential unit. See rear hub assembly
5. Remove 10 locknuts securing differential to axle
case.
6. Withdraw differential unit.
NOTE: The differential unit can only be
serviced as a complete assembly with
matching drive pinion.
5
REPAIR
Refit
7. Ensure mating faces are clean and apply a bead
of RTV sealant to axle case flange.
8. Support differential unit and position on axle
casing.
9. Secure with lock nuts and tighten to 40 Nm,
30lbf/ft.
10. Align marks on flanges and secure propeller
shaft to differential. Tighten bolts to 48 Nm, 35
lbf/ft.
11. Refit half shafts. See Rear hub assembly
12. Refill axle oil with approved lubricant. See
Information, recommended lubricants and
fluids
1
OVERHAUL
REAR HUB ASSEMBLY
Service repair no - 64.15.14.
REAR HUB COMPONENTS
1. Nut - sensor ring
2. Axle shaft.
3. Axle shaft joint washer.
4. Axle shaft retaining bolt - 5 off.
5. Lock nut.
6. Lock washer.
8. Spacing washer.
9. Outer bearing.
10. Hub.
11. Inner bearing.
12. Grease seal.
13. Brake disc.
14. Disc retaining bolt - 5 off.
15. Sensor ring - engine management
51
2
OVERHAUL
Remove
1. Remove rear hub. See Repair, rear hub
assembly
2. Remove outer bearing.
3. Mark, for reassembly, position of hub to brake
disc.
4. Remove 5 bolts and separate hub from brake
disc.
WARNING: A maximum of two road wheel
retaining studs can be renewed. Should
more studs be unserviceable fit new hub
with studs.
5. Remove grease seal and inner bearing from
hub.
6. Remove inner and outer bearing tracks.
Refit
7. Clean hub and fit inner and outer bearing tracks.
8. Pack hub inner bearing with grease and fit to
hub.
9. With lip side leading fit a new seal flush with rear
face of hub. Using service tool LRT-54-003seal
replacer and drift. Apply grease between seal
lips.
10. Assemble brake disc to the hub, line up
reassembly marks. Applying Loctite 270, fit and
tighten retaining bolts to 73 Nm, 55 lbf/ft.
11. Pack hub outer bearing with grease and fit to
hub.
12. Fit rear hub assembly. See Repair, Rear Hub
Assembly
3
OVERHAUL
REAR STUB AXLE
STUB AXLE COMPONENTS
1. Stub axle to axle casing bolt
2. Mudshield
3. Stub axle
4. Stub axle joint washer
5. Axle casing
6. Wheel speed sensor
Overhaul
1. Remove hub assembly. See Repair, Rear Hub
Assembly
2. Remove 6 bolts securing stub axle to axle
casing.
3. Remove mudshield.
4. Remove stub axle and joint washer.
Renew rear stub axle oil seal
5. Remove and discard oil seal. Lubricate seal and
lip with EP90 oil. Using special tool
LRT-51-004(LST.138) fit new oil seal lipside
trailing so that seal is flush with rear face of stub
axle.
Refit
6. Fit new joint washer, stub axle and mudshield
bolts. Tighten bolts to 65 Nm, 50 lbf/ft .
7. Refit hub assembly See Repair, Rear Hub
Assembly
1
TORQUE VALUES
REAR AXLE Nm lbf ft
Drive shaft flange bolts 48 ..................................................... 35
Lower link to axle 176 ............................................................. 130
Pivot bracket ball joint to axle 176 ........................................... 130
Stub axle bolts 65 .................................................................. 50
FRONT AXLE AND FINAL DRIVE
1
DESCRIPTION
The welded steel front axle casing houses a separate
spiral bevel type differential unit, which is off set to the
right of the vehicle centre line. The differential unit
drives the front wheels via the axle shafts and
constant velocity joints which are totally enclosed in
the spherical and swivel housings.
The front wheels are pivoted on a taper roller bearing
at the bottom and a Rialco bush at the top of the
swivel housing. The top swivel also houses the wheel
sensor used by engine management. The wheel hubs
are supported by 2 taper bearings and driven by drive
flanges which are splined to the one piece stub
shaft/constant velocity joint.
Lubrication
The differential, swivel pin housing and wheel hubs
are individually lubricated and separated by oil seals
to prevent oil transfer across the axle when the
vehicle is traversing steep inclines. The wheel
bearings are lubricated with grease and the and
differential with oil. The swivel housings are lubricated
with grease unless the housing is fitted with filler and
level plugs then oil is used.
Ventilation
Ventilation of the differential is through a plastic pipe
which terminates at a high level in the vehicle. The
swivel housings ventilate through the axle shaft oil
seals into the differential and the hub bearings vent
via the oil seals into the swivel housing.
54
2
Front axle
1. Axle casing
2. Ventilation pipe
3. Axle shaft
4. Wheel studs and hub
5. Stub axle
6. Wheel bearings - 2
7. Inner and outer hub seals
8. Axle shaft seal
9. Hub lock plate, thrust washer and nuts - 2
10. Brake disc
11. Drive flange
12. Shim washer and circlip
13. Dust cap
14. Constant velocity joint/shaft
15. Thrust collar for CV joint
16. Roller bearing
17. Spacer
18. Circlip
19. Top and bottom swivel taper bearings
20. Top and bottom swivel pins
21. Spherical housing, seal and retainer
22. Swivel housing
23. Constant velocity shaft seal
24. Speed sensor - engine management
25. Rialco bush - sensor
1
FAULT DIAGNOSIS
FAULT DIAGNOSIS
Complaint - Oil leaks
An external leak of lubrication can be caused by a
faulty internal seal. For example, if the seals which
separate the differential from the swivel housings are
faulty and the vehicle is operating or parked on an
embankment, oil may leak across the axle leaving one
swivel with a high level and the opposite swivel and
differential lacking lubrication.
See Description and Operation for illustration
showing oil seal locations.
When investigating leaks or checking oil levels, it is
essential that all the lubrication is drained from any
housing with a high level and that the other levels are
checked.
Swivel housing oil (where used) should be checked
for signs of grease leaking from the hub bearings and
oil contamination of the hub grease.
Check that the axle ventilation system is clear, as a
blockage can cause internal pressure to force oil past
the seals.
If the vehicle is driven in deep water with defective oil
seals, water may contaminate the lubricants and when
checked, give a false impression that the housing has
been overfilled with oil.
Do not assume that a high oil level is due to over
filling or, that a low level is because of an external
leak.
1
REPAIR
FRONT AXLE ASSEMBLY
Remove
WARNING: Remove and refit of axle
requires a further 2 persons to steady axle
when lowering or repositioning.
1. Raise and support chassis front.
2. Remove front road wheels.
3. Support axle weight with hydraulic jack.
4. Remove both radius arm to chassis frame lock
nuts.
5. Disconnect steering damper from track rod.
Using an extractor remove track rod links from
swivel pin arms.
6. Remove 4 nuts and bolts securing radius arms
to axle bracket.
7. Disconnect radius arms from axle.
8. Remove bolts securing brake hose brackets.
Refit bolts to prevent oil leakage.
9. Remove both wheel sensor lead plugs and
release lead retaining clips.
10. Remove bolts from brake calipers and tie
calipers to one side. DO NOT strain hoses.
11. Remove nuts and washers securing shock
absorbers to axle.
12. Disconnect drag link from swivel pin housing
arm.
13. Remove 2 nuts and bolts securing panhard rod
to axle bracket. Lift rod clear of axle.
14. Mark drive shaft flanges for reassembly .
Remove 4 nuts and bolts, tie propeller shaft to
one side.
15. Release axle ventilation pipe banjo and lower
axle assembly. Remove road springs.
16. Disconnect anti-roll bar link See FRONT
SUSPENSION, Repair, Anti-roll bar ball joint
links .
17. Remove axle assembly.
18. Transfer components to new axle.
Refit
19. Position axle under vehicle, supporting left side
of axle.
20. Fit road springs, axle ventilation pipe banjo and
raise axle assembly.
21. Align reference marks and fit propeller shaft.
Tighten bolts to 47 Nm, 35 lbf/ft.
22. Fit panhard rod to axle bracket. Tighten bolts to
88 Nm, 65 lbf/ft.
23. Fit drag link to swivel pin arm. Tighten fixings to
40 Nm, 30 lbf/ft.
24. Fit shock absorbers to axle.
25. Fit brake calipers. Tighten bolts to 82 Nm, 60
lbf/ft.
26. Tighten upper swivel pin bolts to 65 Nm, 50
lbf/ft.
27. Reconnect both wheel sensor lead plugs and fit
lead retaining clips.
28. Fit radius arms to axle brackets. Tighten bolts to
197 Nm, 145 lbf/ft.
29. Fit steering damper to track rod.
30. Fit radius arms to chassis side member. Tighten
fixings to 197 Nm, 145 lbf/ft .
31. Tighten track rod end to 40 Nm, 30 lbf ft align to
hole and fit NEW split [cotter] pin.
32. Fit road wheels, tighten to 130 Nm, 95 lbf ft.
33. Remove chassis supports.
54
2
REPAIR
FRONT HUB ASSEMBLY
Remove
1. Loosen road wheel nuts, raise front of vehicle
and lower onto axle stands. Remove road wheel.
2. Release brake hose clips and remove brake
caliper and brake disc shield bolts. Secure
caliper to one side.
3. Lever off dust cap.
4. Remove circlip and driveshaft shim from
driveshaft.
5. Remove 5 bolts and withdraw drive member and
joint washer. Discard joint washer.
6. Bend back lock washer tabs.
7. Remove locknut and lock washer.
8. Remove hub adjusting nut.
9. Remove spacing washer.
10. Remove hub and brake disc assembly complete
with bearings.
HUB COMPONENTS
1. Dust cap.
2. Drive shaft circlip.
3. Drive shaft shim.
4. Drive member.
5. Drive member joint washer.
6. Drive member retaining bolt.
7. Lock nut.
8. Lock washer.
10. Spacing washer.
11. Outer bearing.
12. Hub.
13. Inner bearing.
14. Grease seal.
15. Brake disc.
16. Disc retaining bolt.
3
REPAIR
Refit
1. Clean stub axle and drive shaft and fit hub
assembly to axle.
2. Fit spacing washer.
3. Fit hub adjusting nut. Tighten to 50 Nm, 37 lbf ft.
Ensure hub is free to rotate with no bearing play.
4. Back off adjusting nut 90 and tighten to 10 Nm,
7 lbf ft . This will give the required hub end float
of 0,010mm, 0.0004 in.
5. Fit a new lock washer.
6. Fit locknut. Tighten to 50 Nm, 37 lbf ft.
7. Tab over lock washer to secure adjusting nut
and locknut.
8. Fit a new joint washer to driving member and fit
member to hub. Tighten bolts to 65 Nm, 48 lbf
ft.
9. Fit original drive shaft shim and secure with a
circlip.
10. To check drive shaft end play, mount a dial
gauge using bracket LRT-99-503and rest pin in
a loaded condition on end of drive shaft.
11. Fit a suitable bolt to threaded end of drive shaft.
Move drive shaft in and out noting dial gauge
reading. End play should be between 0,08 to
0,25 mm, 0.003 to 0.010 in.
12. If end play requires adjustment, remove circlip,
measure shim thickness and fit an appropriate
shim to give required end-play.
13. Remove bolt from drive shaft, fit circlip and dust
cap.
14. Fit brake disc shield and brake caliper. Tighten
fixings to 82 Nm, 60 lbf ft.
Brake system bleed
16. Fit road wheel, remove axle stands and tighten
road wheel nuts to 130 Nm, 95 lbf ft.
17. Operate footbrake to locate brake pads.
1
OVERHAUL
FRONT DIFFERENTIAL
Overhaul
NOTE: The front axle differential is the
same as that fitted to the rear axle and can
only be serviced as a complete assembly
See REAR AXLE AND FINAL DRIVE, Repair, Rear
differential .
FRONT HUB
Overhaul
1. Remove hub assembly See Repair, Front hub
assembly
2. Remove outer bearing.
3. Mark, for reassembly, relationship between hub
and brake disc, if original hub is to be refitted.
4. Remove 5 bolts and separate hub from brake
disc.
5. Drift out grease seal and inner bearing from hub
and discard seal.
6. Drift out inner and outer bearing tracks.
7. Clean hub and drift in inner and outer bearing
tracks.
8. Pack hub inner bearing with recommended
grease and fit to hub.
9. With lip side leading fit new seal to hub using
special tool LST 137seal replacer and drift 18G
134. Drive in seal flush with rear face of hub.
Apply grease between seal lips.
10. Fit brake disc to hub, lining up to marks made
during dismantling. Apply Loctite 270, fit
retaining bolts. Tighten to 73 Nm, 55 lbf/ft.
11. Grease and fit outer bearing to hub.
12. Fit hub assembly. See Repair, Front hub
assembly
54
2
OVERHAUL
FRONT STUB AXLE, CONSTANT VELOCITY JOINT
AND SWIVEL PIN HOUSING
Remove stub axle, axle shaft and constant
velocity joint.
1. Remove front hub assembly. See Repair,
Front Hub Assembly
2. Drain swivel pin housing and refit plug.
NOTE: On later vehicles the swivel pin
housing is filled with grease for life
service. The level and drain plugs have
been deleted.
3. Remove 6 bolts retaining stub axle to swivel
housing.
4. Remove mud shield.
5. Remove stub axle and joint washer.
6. Pull out axle shaft and constant velocity joint
from axle casing.
Remove constant velocity joint from axle shaft
7. Hold axle shaft firmly in a soft jawed vice.
8. Using a soft mallet drive constant velocity joint
from shaft.
9. Remove circlip and collar from axle shaft.
Constant velocity joint
10. Mark positions of constant velocity joint, inner
and outer race and cage for reassembly.
11. Swivel cage and inner race to remove balls.
3
OVERHAUL
12. Examine all components in particular inner and
outer track, cage balls and bearing surfaces for
damage and excessive wear.
13. Maximum acceptable end-float on assembled
joint 0,64mm, 0.025 in. Renew if worn or
damaged. Lubricate with a recommended oil
during assembly.
Fit constant velocity joint to axle
14. Fit collar and a new circlip.
15. Engage constant velocity joint on axle shaft
splines and using a soft mallet, drive joint in fully.
Renew stub axle,thrust ring, oil seal and bearing
16. Drill and chisel off thrust ring taking care to avoid
damaging stub axle.
17. Remove bearing and oil seal using special tool
LRT-37-004and slide hammer LRT-99-004.
Ensure lip of tool locates behind bearing to to
drive it out.
18. Repeat instruction for removal of oil seal.
19. Lubricate seal and lip with EP90 oil and with
cavity side leading press in a new oil seal using
special tool LRT-54-004.
20. Using special tool LRT-54-005, fit bearing with
its part number visible when fitted, and flush with
end face of stub axle.
21. Press fit a new thrust ring onto stub axle.
54
4
OVERHAUL
Swivel pin housing assembly
22. Remove brake disc shield bracket.
23. Disconnect track-rod end ball joint from housing.
24. Disconnect drag-link ball joint.
25. Disconnect jump hoses from brake jump hose
bracket.
26. Remove road speed sensor.
27. Remove 6 bolts securing oil seal and retaining
plate to swivel pin housing. Prise seal from
swivel pin housing.
NOTE: Oil seal and retaining plate cannot
be removed until swivel pin bearing
housing is removed.
28. Remove 2 screws securing brake damper/shield
bracket, and lower swivel pin to housing.
29. Withdraw lower swivel pin and joint washer by
tapping protruding lug.
30. Remove top swivel pin retaining bolts complete
with brake jump hose bracket.
31. Remove top swivel pin and shims.
32. Remove swivel pin housing while retrieving
lower taper bearing.
Swivel pin bearing housing
33. Remove 7 bolts securing swivel pin bearing
housing to axle case.
34. Remove and discard oil seal and joint washer.
35. Remove lower swivel pin bearing track.
36. Remove top swivel pin bush housing assembly.
Discard two thrust washers and bearing.
37. If worn, pitted or damaged, renew swivel pin
bearing housing.
38. Fit a new lower swivel pin bearing track.
39. Fit a new bush and bush housing. Ensure
relieved lip of bush housing faces towards rear,
as shown.
40. With seal lips trailing press axle shaft oil seal
flush into rear of housing. Grease lips.
41. Fit new thrust washers and bearing into top
swivel pin bush.
42. Hang swivel pin bearing housing oil seal and
retainer plate over back of housing. Ensure they
are in correct assembly order.
43. Fit a new joint washer and secure swivel pin
bearing housing to axle. Starting with top fixing
dowel bolt. Tighten to 72Nm, 52 lbf ft.
Fit swivel pin housing
44. Grease and fit lower swivel pin bearing to
bearing housing.
45. Place swivel pin housing in position over swivel
pin bearing housing.
46. Using a new joint washer, fit lower swivel pin
with lip outboard. Do not secure with screws at
this stage.
47. Fit a new sensor bush and new oil seal, lip side
leading to top swivel pin.
48. Lubricate with a recommended oil and fit top
swivel pin with existing shims.
49. Coat threads of top swivel pin bolts with Loctite
542. Fit bolts and jump hose bracket (do not
tighten).
50. Coat threads of lower swivel pin screws with
Loctite 270 and fit, together with damper and
shield bracket. Tighten to 25 Nm, 18 lbf ft.
51. Tighten top swivel pin and brake jump hose
bracket securing bolts to 65 Nm, 50 lbf ft.
Check and adjust preload on bearings
52. The preload on bearings to be 0,25 to 0,30 mm,
0.010 to 0.012 in without swivel housing oil seal
and axle fitted, and reading from centre of swivel
pin. The torque required to turn swivel assembly
from lock to lock to be 2.0 to 2.8 Nm, 1.5 to 2.0
lbf ft. Adjust by removing or adding shims as
necessary.
53. To take a reading use special tool
LRT-57-024torque test adaptor, with a torque
wrench and extension as shown.
5
OVERHAUL
54. Apply a recommended grease between lips of
swivel housing oil seal.
55. Secure oil seal with retaining plate and securing
bolts. Tighten to 11Nm, 8 lbf ft.
56. Fit track-rod and drag link and secure with new
cotter pins.
57. Loosely fit lock stop bolt for later adjustment.
58. Fit brake disc shield.
Fit driveshaft and stub axle
59. Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60. Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61. Fit stub axle with flat at 12 Oclock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle before stub axle is
secured.
62. Place mud shield in position and secure stub
axle to swivel pin housing with six bolts and
tighten evenly to 65 Nm, 48 lbf ft.
63. Fit brake jump hoses to brake jump hose
bracket.
64. Fit front hub complete assembly. See Repair,
Front Hub Assembly
65. Fill swivel assembly with correct amount of
lubricant. See SECTION 10, Maintenance,
Under vehicle maintenance .
NOTE: Vehicles with a filler plug only must
be filled with 0.33 Litres, 0.75 pt of Molytex
EP 00 grease.
66. Set steering lock stop bolts. See STEERING,
Adjustment, Steering Lock Stops
67. Fit Wheel speed sensor. See FUEL SYSTEM,
Repair, Wheel speed sensor - Front
1
TORQUE VALUES
FRONT AXLE Nm .................................................................. lbf/ft
Hub driving member to hub 65* .............................................. 48*
Brake disc to hub 73 ............................................................. 55
Stub axle to swivel pin housing 65* ........................................ 50*
Brake caliper to swivel pin housing 82 .................................. 60
Upper swivel pin to swivel pin housing 65* ............................. 48*
Lower swivel pin to swivel pin housing 25* ............................. 18*
Oil seal retainer to swivel pin housing 11 .............................. 8
Swivel bearing housing to axle case 73* ................................ 55*
Differential drive flange to propeller shaft 47 ......................... 35
Mudshield to bracket lower swivel pin 11 .............................. 8
Bevel pinion nut 130 ................................................................ 95
Draglink to swivel pin arm 40 ................................................ 30
Panhard rod to axle bracket 88 ............................................. 65
Radius arm to axle bracket 190 .............................................. 140
Radius arm to chassis side member 190 ................................ 140
Track rod end 40 ................................................................... 30
Hub adjusting nut 50 ............................................................. 37
Road wheel nuts 130 .............................................................. 95
NOTE: * These bolts to be coated with Loctite 270 prior to assembly.
STEERING
1
DESCRIPTION
The steering system incorporates a compression joint
in the lower shaft and is designed to collapse on
impact. The misalignment of the upper steering
column with the steering box and the inclusion of two
universal joints, is also designed to prevent the
column moving towards the driver under frontal
impact.
The steering box is located behind the first chassis
cross member and is connected to the road wheel
swivel housing by a drag link and track rod. An
hydraulic damper absorbs shocks in the steering,
caused by road wheel deflections when operating on
rough terrain.
Power steering system
The power steering system comprises an hydraulic
pump which is belt driven from the engine and
supplied with fluid from a reservoir that also acts as a
cooler.
The steering box houses a self neutralizing rotary
valve which is part of the worm/valve assy and an
hydraulic piston/rack to assist the mechanical
operation. The rotary valve which is operated by
movement of the steering wheel, directs fluid pressure
to the appropriate side of the hydraulic piston/rack to
provide assistance.
Power steering system
1. Hydraulic pump
2. Fluid reservoir
3. Steering box
4. Upper column
5. Universal joints
6. Lower shaft
7. Compression joint
8. Drag link
57
STEERING
2
Power steering box components
1. Housing complete with sector shaft bearings
2. Cover plate complete with bearing
3. Sector shaft
4. Hydraulic piston/rack
5. Worm/valve and torsion bar assembly
6. Shims for centralizing worm/valve
7. Ball race - 2 off
8. Teflon seals for valve sleeve - 3 off
9. Bearing adjuster, locknut and seal
10. Worm shaft pressure seal, circlip and dirt
excluder
11. Teflon and rubber seal for piston
12. End cover seal and snap ring
13. Adjustment components for piston/rack
14. Hydraulic pipe
15. Bleed screw
16. Sector shaft adjustment lock nut with seal
17. Cover plate bolts - 4 off
18. Cover plate seal
19. Seal, washer and backup seal
20. Circlip and dust cover
STEERING
3
Rotary valve operation
The rotary valve assembly comprises a worm (1),
valve sleeve (2), input shaft (4) and torsion bar (5).
The valve sleeve is retained inside the worm by a trim
screw (3), and incorporates valve ports in its inner
bore. The input shaft is attached to the steering wheel
via a steering shaft and steering column and
incorporates valve ports in its outer diameter to align
with those in the sleeve. The torsion bar which is
secured to the worm and input shaft with pins (6) at
each end holds the valve ports in neutral alignment
when there is no demand for assistance.
No demand for assistance (Valve at neutral)
When there is no demand for assistance, the torsion
bar holds the input shaft and sleeve valve ports in
neutral relationship to one another, allowing equal
pump pressure A to both sides of the piston/rack (9).
Any excess fluid flow from the pump returns to the
reservoir via B.
Rotary valve at neutral
57
STEERING
4
Demand for assistance (Valve misaligned)
When the steering wheel and input shaft is turned,
steering resistance transmitted to the worm causes
the torsion bar to be twisted and the valve ports to be
misaligned for a right or left turn. The misalignment of
the valve ports directs all fluid pressure A to one side
of the piston only and allows displaced fluid B on the
other side.
When demanding maximum assistance, any
excessive fluid output from the pump due to high
pump speed, will circulate through the regulator valve
located in the pump unit, causing the temperature of
the fluid and the pump to rise rapidly.
CAUTION: To avoid excessive fluid
temperatures which could damage the oil
seals, the steering must not be held on full
lock for more than 30 seconds in one minute.
Only when the steering wheel, and hence the demand
for assistance is released, will the torsion bar return
the valve to neutral, allowing the fluid to circulate
through the reservoir where it is cooled.
In the unlikely event of mechanical failure of the
torsion bar, a coarse splined connection (7) between
the input shaft and worm, ensures steering control is
maintained sufficient to allow the vehicle to be
recovered.
Rotary valve misaligned
STEERING
5
Pump and regulator valve operation
The pump which is belt driven from the engine is an
eccentric roller type and also houses the pressure
regulator and flow control valve. The pressure is
controlled by a spring loaded ball valve (3) which is
housed inside the flow control valve piston (4).
No demand for assistance
High flow through box - Low pressure
With no demand for assistance the rotary valve in the
steering box acts as a pressure relief valve, allowing
fluid A to flow freely through the steering box and
back to the reservoir and pump inlet B.
1. 1. Reservoir
2. 2. Pump
3. 3. Pressure control ball valve and spring
4. 4. Flow control valve and spring
5. 5. Press fit plug (ball bearing)
6. 6. Restrictor
The ball plug (5) is pressed into the valve 4 during
manufacture and determines the opening
pressure of pressure relief valve (3).
No demand for assistance
No flow, through box - High pressure
When the steering is turned, the rotary valve
effectively stops all fluid flow through the steering box,
thus causing an increase in pressure A. This
increase in pressure is felt in the flow control valve
spring chamber where, at a pre-determined pressure
the relief valve (3) will open and allow the pressure to
escape. The fall in pressure in the flow control spring
chamber, allows the flow control valve to move to the
right, which in turn allows pump output A to escape
directly into the pump inlet B.
As soon as the steering wheel is released after
making a turn, the system reverts to the free flow
condition and the road wheels are returned to the
straight ahead position by the mechanical steering
geometry.
In the event of any hydraulic failure steering control,
though heavy, will be maintained through the
mechanical components in the steering box.
STEERING
1
FAULT DIAGNOSIS
INSUFFICIENT POWER ASSISTANCE
1. Is fluid level correct?
YES - go to 3.
NO - Fill/bleed sytem
2. Is problem a leak?
YES - Diagnose See Power Steering Fluid
Leaks .
NO - continue
3. Is drive belt tension correct?
YES - go to 5.
NO - retension See ELECTRICAL, Repair,
Auxiliary drive belt
4. Is problem resolved?
YES - end
NO - continue
5. Carry out pressure test at idle and 1000 rev/min.
See Power Steering System - Test .
6. Is correct pressure achieved?
YES - steering box defective
Not at any speed go to 9.
Not at idle go to 7.
7. Is idle speed correct?
YES - Go to 8.
NO - Correct idle speed - See FUEL SYSTEM,
Adjustment, Engine tuning .
YES - end
NO - go to 9.
9. Bypass steering box using adaptor tap
LRT-57-001
10. Is correct pressure obtained?
YES - defective steering box
NO - defective steering pump
CAUTION: Do not hold steering wheel on
full lock for more than 30 seconds in any
one minute to avoid overheating fluid and
possibly damaging seals.
NOTE: 1. Excessive pressure in the
system is almost always caused by a
faulty relief valve in the PAS pump.
NOTE: 2. Insufficient pressure in the
system is usually caused by low fluid level
or PAS pump drive belt slip, or one of the
following: PAS system leaks, faulty PAS pump
relief valve, fault in steering box valve and worm
assembly, leak at piston in steering box, worn
components in PAS pump or box.
57
STEERING
2
FAULT DIAGNOSIS
POWER STEERING SYSTEM - TEST
NOTE: If steering lacks power assistance.
Check pressure of hydraulic pump before
fitting new components. Use fault
diagnosis chart to assist in tracing faults.
A. Steering box.
B. Steering pump.
C. Existing hose, steering box to pump.
D. Hose LRT-57-030.
E. Test adaptor LRT-57-001.
F. Pressure gauge LRT-57-005.
G. Thread adaptor LRT-57-004.
H. Thread adaptor LRT-57-022.
Procedure
1. A hydraulic pressure gauge and test adaptor is
used to test power steering system. This gauge
is able to measure 140 kgf/cm
2
, 2000 lbf/in
2
.
The maximum power steering system pressure
is 77 kgf/cm
2
, 1100 lbf/in
2
.
2. Some fault conditions of hydraulic pump may
obtain pressures up to 105 kgf/cm
2
, 1250 lbf/in
2
.
Pressure on gauge is same pressure being
exerted upon steering wheel. When testing, turn
steering wheel gradually while reading pressure
gauge.
3. Check and maintain maximum fluid level of
reservoir.
4. Examine power steering units and connections
for leaks. All leaks must be rectified before
attempting to test the system.
5. Check steering pump drive belt tension See
ENGINE, Repair, Drive Belt .
6. Assemble test equipment and fit to vehicle, as
shown in RR3959M.
7. Open tap of adaptor.
8. Bleed system, take care not to overload
pressure gauge.
9. With system in good condition, pressures should
be:
(A) Steering wheel held on full lock and engine
running at 1,000 rev/min, 70 to 77 kgf/cm
2
, 1000
to 2000 lbf/in
2
.
(B) Steering wheel held on full lock and engine
idling, 28 kgf/cm
2
, 400 lbf/in
2
.
Checks should be carried out on both full lock
positions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute to avoid overheating fluid and
10. Release steering wheel and with engine idling.
Pressure should read below 7 kgf/cm
2
, 100
lbf/in
2
.
11. If pressures differ to those given a fault exists.
12. To determine if fault is steering box or pump.
Close adaptor tap for a maximum five seconds.
13. If gauge does not register specified pressure,
pump is faulty.
14. Fit a new pump, bleed system and repeat test. If
low pressure or a substantial imbalance exists,
fault is in steering box valve and worm
assembly.
STEERING
3
FAULT DIAGNOSIS
STEERING DAMPER
The power steering system, as well as reducing the
effort required to manoeuvre the vehicle when
parking, also helps to dampen any deflections of the
road wheels, being transmitted back to the steering
wheel.
When operating the vehicle off road, the road wheels
are often deflected by ruts and boulders causing the
steering wheel to turn left and right. This phenomenon
is known as steering kickback. To subdue the effects
of steering kickback, a hydraulic damper is fitted in
the steering linkage between the track rod and the
differential casing. The damper, which offers the same
resistance in extension and compression, is sealed for
life.
Steering damper check
Check the condition operation of the hydraulic
steering damper as follows:
Check procedure
1. Inspect damper for casing damage or leaks.
2. Clamp one end of the damper horizontally in a
vice using soft jaws. Compress and extend the
unit by hand. Resistance should be equal in both
directions.
3. If it is felt that the unit is outside acceptable
limits, fit a new steering damper
STEERING FAULTS
Symptom:-
Excessive kickback through steering wheel - when
driven on rough terrain.
1. Is the steering damper in good working order?
See Steering Damper.
NO - Renew unit See Repair, Steering
Damper.
YES - Continue.
2. Is there any looseness or free play in the
steering ball joints and linkage?
YES - See Steering Linkage Inspect.
NO - Continue.
3. Is there any looseness or worn bushes in front
suspension?
YES - See FRONT SUSPENSION, Repair,
Radius Arm.
NOTE: When replacing suspension bushes
ALL bushes and fixings must be replaced.
NO - Continue.
4. Is the steering exceptionally light/sensitive when
driven on good road surface?
YES - See fault symptom - Steering
excessively light/sensitive and freeplay at
steering wheel.
NO - Suspect axle swivel resistance.
5. Check the resistance of the axle swivels See
FRONT AXLE AND FINAL DRIVE, Overhaul,
Front Stub Axle, Constant Velocity Joint and
Swivel Pin Housing.
57
STEERING
4
FAULT DIAGNOSIS
Symptom:-
Fluid leaks from steering box seals.
CAUTION: The steering wheel must not be
held on full lock for more than 30 seconds
in one minute, as this may overheat the
fluid and cause damage to the oil seals.
1. Check fluid level See Repair, Power Steering
Fluid Reservoir.
Check fluid pressure See Power Steering
System - Test.
2. Is pressure high?
YES - Renew pump See Repair, Power
steering Pump.
If oil seal leaks persist after renewing the pump
See Overhaul, Power Steering Box.
NO - See Overhaul, Power Steering Box.
Symptom:-
Insufficient power assistance - castor return
action normal.
1. Are tyres correct type and pressure?
NO - See GENERAL SPECIFICATION DATA,
Information, Wheels and Tyres.
YES - Continue.
NO - Check fluid level See Repair, Power
Steering Fluid Reservoir.
YES - Check system for air locks See Repair,
Power Steering System - Bleed.
3. Is pressure correct?
NO - Check fluid pressure See Power Steering
System - Test.
If pressure is not correct after bleeding the
system, renew pump See Repair, Power
Steering Pump.
YES - See Overhaul, Power Steering Box.
Symptom:-
Steering heavy - stiff, poor castor return action.
1. Are tyres correct type and pressure?
NO - See GENERAL SPECIFICATION DATA,
Information, Wheels and Tyres.
YES - Check universal joints for seizure and
correct alignment See Repair, Lower Steering
Shaft and Universal Joints .
Check power steering box adjustments See
Overhaul, Power Steering Box.
2. Is the power assistance satisfactory?
NO - See fault symptom Insufficient
assistance, (castor return action normal).
YES - Disconnect drag link from drop arm and
check steering column and box for stiffness See
Repair, Drag Link and Drag Link Ends.
3. Is the steering stiff with the drag link
disconnected?
NO - Check steering ball joints for seizure and
axle swivels lubrication and resistance See
Repair, Drag Link and Drag Link Ends , See
Swivel Pin Housing.
YES - Disconnect the lower steering shaft and
check the column and box for stiffness See
Repair, Lower Steering Shaft and Universal
Joints.
4. Is the steering column stiff to turn when
disconnected from the box?
NO - Remove and overhaul box See Overhaul,
Power Steering Box.
YES - Adjust steering column See Stiff
Steering Checklist.
STEERING
5
FAULT DIAGNOSIS
Symptom :-
Steering excessively light/sensitive. Excessive
freeplay at steering wheel.
1. Are steering box adjustments correct?
NO - See Adjustment, Power Steering Box.
WARNING: Adjustments of steering box
should not be required while in warranty
period. If box is within warranty, it must be
returned to manufacturer. No attempt must be
made to introduce backlash.
YES - Suspect worn panhard rod or radius arm
bushes. Check condition of ball joints and the
lower steering column shaft universal joints for
wear See Repair, Lower Steering Shaft and
Universal Joints.
Symptom :-
Steering vibration, road wheel shimmy - wobble.
Vibration through the steering linkage powerful
enough to induce high frequency oscillation of the
steering wheel, is generally caused by out of balance
road wheels. However there are a number of other
possible causes of this symptom which if severe, may
be described as shimmy or wobble. Regardless of the
terminology used by the owner/driver to describe the
symptoms, the following diagnostic checks should be
carried out in the order presented.
1. Check the tyres and balance of the road wheels
See GENERAL SPECIFICATION DATA,
Information, Wheels and Tyres , See
WHEELS AND TYRES, Fault diagnosis, Fault
- Symptoms See WHEELS AND TYRES,
Repair, Wheel Balancing.
2. Check the steering hydraulic damper function
See Steering Damper.
3. Check steering column universal joints for wear
and correct alignment See Repair, Lower
Steering Shaft and Universal Joints.
4. Check steering linkage ball joints for wear,
correct alignment and security, including steering
box and tie rod, See Steering Linkage
Inspect.
5. Check all front suspension rubbers for wear.
Check all fixing torques, including radius arm
bushes, panhard rod and anti-roll [sway] bar
See FRONT SUSPENSION, Repair, Panhard
Rod, See FRONT SUSPENSION, Repair,
Radius Arm, See FRONT SUSPENSION,
Repair, Anti-Roll Bar Assembly, See FRONT
SUSPENSION, Repair, Front Shock
Absorber.
6. Fit new radius arm bushes using NTC 6860. Fit
new nuts, bolts and washers.
7. If problem persists fit damper kit STC 241 (2 off
front) and STC 1474 (2 off rear). Road test
vehicle.
8. Check the power steering box adjustments and
operation See Overhaul, Power Steering Box.
9. Check the hub bearing end floats and determine
the condition of the hub bearings as applicable
See FRONT AXLE AND FINAL DRIVE, Repair,
Front Hub Assembly.
10. Check the resistance and condition of the
swivels See FRONT AXLE AND FINAL DRIVE,
Description and operation, Description.
If problem is not diagnosed: Repeat checks
starting at 1.
11. Carry out a full steering geometry check See
INTRODUCTION, Information, Steering.
57
STEERING
6
FAULT DIAGNOSIS
STEERING STABILITY AND VEER UNDER
BRAKING
Possible cause:
Incorrectly set, swivel pin bearing preload.
Remedy.
1. Follow instructions to overhaul front stub axle,
constant velocity joint and swivel pin See
Swivel Pin Housing.
1. GENERAL STEERING
1. Carry out visual and safety checks See Visual
and Safety Checks.
2. Road test vehicle See Road Test Procedure .
YES - end
NO - continue
4. Is problem stiff steering?
YES - See Stiff Steering Checklist .
NO - Go to 6.
YES - end
NO - go to 8.
6. Is problem steering niggle ?
YES - Replace radius arm bushes, arm and axle
See FRONT SUSPENSION, Repair, Radius
Arm.
NO - go to 8.
YES - end
NO - continue.
8. Centralise steering box See Adjustment,
Centralise Steering Box.
YES - end
NO - continue.
10. Check, adjust if necessary, steering geometry.
YES - end
NO - continue.
12. Categorise the remaining problems into one or
more of the following descriptions:
See 2. Steering Veer .
See 3. Veer Under Braking .
See 4. Directional Stability .
STEERING
7
FAULT DIAGNOSIS
2. STEERING VEER
From 1. GENERAL STEERING:
1. Vehicle veers, not under braking, swap front
tyres side to side.
YES - end
NO - continue.
3. Does vehicle now veer in other direction?
YES - fit new tyres
NO - continue.
4. Recentralise steering box See Adjustment,
Centralise Steering Box.
YES - end
NO - contact local technical office.
3. VEER UNDER BRAKING
1. Vehicle veers under braking, bleed brake
system.
YES - end
NO - continue.
3. Check brake pads for glazing, and discs, axles
etc for contamination.
YES - end
NO - continue.
5. Check brake lines and hoses for deterioration.
Replace as necessary.
YES - end
NO - continue.
7. Contact Technical Support Office.
57
STEERING
8
FAULT DIAGNOSIS
4. DIRECTIONAL STABILITY
1. Is directional stability concern when vehicle is
towing?
YES - Check towing/vehicle loading parameters
in Owners Handbook.
NO - go to 3.
YES - end
NO - continue.
3. Check condition of rear trailing link/chassis
bushes.
YES - end
NO - continue.
5. Check condition of front and rear shock
absorbers. If in doubt change units in pairs, side
to side.
YES - end
NO - continue.
7. Check steering damper See Steering Damper.
YES - end
NO - continue.
9. Check wheel balance
YES - end
POWER STEERING FLUID LEAKS
YES - go to 3.
NO - Refill or drain to correct level. Bleed
system, check for leaks See Repair, Power
Steering System - Bleed.
YES - end
NO - continue.
3. Are hoses or joints leaking? Check on full lock
with engine at 2000 rev/min.
YES - loosen and retorque joints.
NO - go to 6.
4. Does leak remain?
YES - change PAS pipe.
NO - end.
5. Does leak remain?
YES - suspect seal in component. Check and
replace as necessary.
NO - end.
6. Is oil escaping from filler cap?
YES - bleed system See Repair, Power
NO - go to 8.
7. Is oil still escaping from filler cap?
YES - go back to 1.
NO - end.
8. Is oil leaking from PAS pump?
YES - go to 10.
NO - continue.
9. Is oil leaking from PAS box?
YES - go to 10.
NO - end.
10. Clean unit, add tracer dye to system. Retest
11. Is oil still leaking?
YES - establish leak point. Repair or replace unit
as necessary.
NO - end.
STEERING
9
FAULT DIAGNOSIS
POWER STEERING SYSTEM - EXCESSIVE NOISE
YES - go to 3.
NO - Refill or drain to correct level. Bleed
system, check for leaks See Repair, Power
YES - end
NO - continue.
3. Is pressure hose from pump to box touching
body in a hard foul condition?
YES - reroute hose away from body.
NO - go to 5.
4. Does noise remain?
YES - continue.
NO - end.
5. Is noise a whistle or hiss on full lock?
YES - noise is not a fault unless excessive.
Compare with other vehicles
NO - go to 8.
6. Is noise excessive?
YES - continue.
NO - end.
7. Change steering box and/or pump.
8. Is noise a squeal on full lock?
YES - checkdrive belt tension See
ELECTRICAL, Repair, Auxiliary drive Belt.
NO - go to 10.
9. Does squeal remain?
YES - drive belt contaminated, change belt See
ELECTRICAL, Repair, Auxiliary drive belt.
NO - end.
10. Is noise a continuous moan?
YES - bleed PAS system See Repair, Power
NO - go to 13.
11. Does moan remain?
YES - do figure 8 manoeuvres.
NO - end.
12. Does moan remain?
YES - continue
NO - end.
13. Is noise an intermittent "grunt"?
YES - See Power Steering System - Grunt.
NO - continue.
14. Is it a clunking noise?
YES - check drive belt tension See
15. Does noise remain?
YES - Suspect suspension or drive train.
NO - end.
POWER STEERING SYSTEM - GRUNT
Steering box grunts intermittently when turning
from lock to lock:
YES - go to 3.
NO - refill or drain to correct level. Bleed system,
check for leaks See Repair, Power Steering
System - Bleed.
2. Does grunt remain?
YES - continue
NO - end.
3. Is correct low pressure hose, steering box to
reservoir fitted?
YES - go to 5.
NO - Fit correct hose.
YES - continue
NO - end.
5. Purge box by doing figure 8 manoeuvres e.g. on
car park, followed by 10 minutes normal road
use.
YES - Contact local technical office
NO - end.
57
STEERING
10
FAULT DIAGNOSIS
VISUAL AND SAFETY CHECKS
WARNING: Before taking vehicle out on
the public highway for road test, it is
important that the following basic visual
checks are carried out to ensure that the vehicle
complies with legal requirements.
Tyres and wheel rims
1. Check and adjust tyre pressures See GENERAL
SPECIFICATION DATA, Information, Tyre
Pressures.
Note that this information refers to standard tyres
fitted as original equipment.
2. Check condition of tyres. Inspect for signs of
uneven wear, damage and feathering. Check
tread depth.
3. Ensure that the tyre make, type and general
condition are common across each axle.
4. Check wheel rims for signs of damage and
excessive run out.
5. Carry out road test See Road Test Procedure.
ROAD TEST PROCEDURE
General steering/handling problems can usually be
classified into one of the categories listed and ARE
GENERALLY RELATED TO THE AGE, CONDITION
AND USE OF THE VEHICLE.
WARNING: Ensure that all road tests are
conducted by suitably qualified drivers in
a safe and legal manner, and where local
traffic conditions allow.
1. Carry out visual and safety checks See Visual
and Safety Checks .
Confirm general nature of complaint with customer,
simulating where possible the conditions under which
the problem occurs. Carry out following road test
procedure to establish the problem.
2. Steering load assessment - drive at 15 km/h, 10
mph. Put 90turn input into steering wheel,
check self centering. The self centering should
be equal on each lock but not necessarily return
to exactly straight ahead without assistance from
the driver.
3. Steering assessment - drive at 65 km/h, 40 mph
on a staight FLAT road (no camber), check for
steering veer. The vehicle should follow a
straight path with NO tendency to follow a
curved path. If vehicle veers towards the kerb,
vehicle may be camber sensitive. A small
amount of veer in direction of camber is
acceptable.
4. Directional stability assessment - drive at 110
km/h, 70 mph or maximum legal speed on a
straight flat road. Carry out a normal lane
change. Vehicle should quickly settle into a new
straight path.
5. Braking assessment (medium effort) - drive at 95
km/h (60 mph) on a straight flat road. Apply
steady medium braking effort, noting any
tendency to veer. Carry out brake test three
times, if a veer is consistently noted carry out a
braking efficiency test on a rolling road.
6. Braking assessment (full effort) - drive at 95
km/h, 60 mph on a straight flat road. Apply full
braking effort, noting any tendency to veer. Carry
out brake test 3 times, if a veer is consistently
noted carry out a braking efficiency test on a
rolling road.
If the symptom described by the customer is stiff
steering or steering niggle, carry out stiff steering
procedure See Stiff Steering Checklist.
If not, proceed with basic checks and adjustments
See Visual Check and Basic Adjustments .
STEERING
11
FAULT DIAGNOSIS
STIFF STEERING CHECKLIST
NOTE: Having completed visual checks
and steering assessment and confirmed
that vehicle steering load is incorrect carry
out the following procedure in order shown.
Steering wheel torque to turn loads
1. Raise vehicle so both front wheels free.
2. With engine off, centralise steering wheel, and
remove steering wheel pad. Using torque
wrench on column nut, check torque required to
turn the steering wheel one turn in each
direction.
3. Record readings obtained in each direction.
Reading should be 4.4 Nm, 3.5 lbf ft .
NOTE: If figures are in excess of that
specified carry out steering box tie bar
reset below. If figures are as specified See
Visual Check and Basic Adjustments .
Steering box tie bar reset
1. Loosen the tie bar fixings one complete turn.
2. Drive vehicle carefully a short distance, within
the dealership, applying full lock in both
directions in order to settle steering components.
Drive vehicle over speed bumps and include
harsh braking if possible.
WARNING: Do not drive on public
highway.
3. Near end of 2. ensure vehicle is driven in a
straight line on level ground and halted.
4. Tighten panhard rod mounting arm nut to110
Nm, 80 lbf ft .
5. Tighten the 2 fixings, tie bar to steering box, to
80 Nm, 60 lbf ft .
6. Recheck steering wheel torque to turn. If torque
reading is still greater than specified, carry out
steering shaft universal joint lubrication.
Lower steering shaft universal joint lubrication
1. Check lower steering shaft is correctly phased
See Repair, Lower Steering Shaft and
Universal Joints.
2. Lubricate universal joints with an anti-seizure
type penetrating spray. Work the joints to ensure
full penetration of the spray by driving vehicle
and steering from lock to lock.
3. If steering stiffness still persists carry out swivel
pin preload setting.
Swivel pin preload setting
1. The swivel pin preload setting must be checked
and set See FRONT AXLE AND FINAL DRIVE,
Overhaul, Front Stub Axle, Constant Velocity
Joint and Swivel Pin Housing.
Note that a pull load of 1.16 - 1.46 kg, 2.5 - 3.2 lb
is required after the axle shaft and swivel
housing seal have been removed.
Steering box adjustment
1. Check steering box adjustment See
Adjustment, Power Steering Box.
Steering damper check
1. Check condition of steering damper See
Steering Damper.
57
STEERING
12
FAULT DIAGNOSIS
VISUAL CHECK AND BASIC ADJUSTMENTS
NOTE: It is important that the following
instructions are carried out in the
sequence shown and the results recorded.
1. Road springs - check that road springs are
correctly seated and are to correct specification
for vehicle. For spring specification See
GENERAL SPECIFICATION DATA,
Information, Road Springs Data.
2. Ride height - measure trim height from wheel
centre to wheelarch eyebrow. Record results on
Check Sheet.
3. Check/top up power steering fluid See Repair,
Power Steering Fluid Reservoir.
4. Check tension and condition of drive belt See
5. Track rod/drag link - check condition of track rod,
drag link and ball joints See Repair, Drag Link
and Drag Link Ends.
If either component is damaged, check operation
of steering damper and steering box for
smoothness. Replace all damaged or worn
components that impair the operation of the
steering system.
6. Suspension bushes - examine all steering and
suspension bushes for signs of wear and
deterioration. Also check all fixings for torque
relaxation. Tighten to correct torque value See
FRONT SUSPENSION, Specifications, torque,
Torque Values.
7. Oil leaks - check front and rear axle hubs for
leak and repair as necessary.
8. Brake system - check brake system for leaks,
pipe condition, pad wear/contamination, disc
wear/condition.
9. Hub end float - check movement in the hubs by
rocking the wheels.
10. Check front wheel alignment. Vehicles displaying
a tendency to veer more than considered
allowable, it is permissible to set the front track
to parallel.
11. Having completed all the above checks and
adjustments, road test vehicle See Road Test
Procedure .
Attempt to reproduce the symptoms established
earlier. If symptoms still exist refer to relevant
Diagstic Chart.
STEERING LINKAGE INSPECT
NOTE: When inspecting steering linkages
and ball joints for wear the following items
must be checked.
Steering ball joints
1. Check ball joint rubber boots for security, signs
of cracking or deterioration.
2. Check ball joint assemblies for seizure i.e. no
movement on ball joint and associated
assemblies.
3. Check for excessive wear. This will be evident
as extreme movement on track rod and steering
linkages. Renew parts as necessary See
Repair, Track Rod and Linkage, See Repair,
Drag Link and Drag Link Ends.
Steering linkages
1. Check all linkages for wear, deterioration and
damage. Renew parts as necessary See
Repair, Track Rod and Linkage, See Repair,
Drag Link and Drag Link Ends.
STEERING
1
ADJUSTMENT
POWER STEERING BOX - ADJUST
WARNING: Adjustments of steering box
should not be required while in warranty
period. If box is stiff or tight and within
warranty, it must be returned to manufacturer. No
attempt must be made to introduce backlash.
1. Apply park brake brake, select P and chock
road wheels.
2. Jack up front of vehicle until wheels are clear of
ground.
3. Support chassis front on axle stands.
4. Disconnect drag link from steering drop arm.
5. Centralise steering box See Power Steering
Box - centralise
NOTE: Only check for no backlash when
steering box is in central position.
NOTE: If steering wheel is not straight, it
should be repositioned.
6. Adjustment is obtained by rocking the drop arm
about centre whilst an assistant slowly tightens
the steering box adjuster screw.
7. Tighten locknut when all backlash has been
removed.
8. Repeat the check for backlash. If backlash exists
loosen locknut and repeat adjustment
procedure.
9. Turn steering wheel lock to lock and check no
tightness exists.
10. Ensure front wheels are aligned and in straight
ahead position.
11. Adjust drag link 924 mm, 36.2 in between ball
joint centres.
12. Connect drag link and tighten to 40 Nm, 30 lbf
ft.
13. Lower vehicle to ground level and remove
chocks.
14. Road test vehicle .
Drag link adjust
1. If steering wheel is to right, drag link is too short.
If steering wheel is to left drag link is too long.
2. Adjust drag link until steering wheel points
straight ahead when vehicle is travelling in a
straight line.
57
STEERING
2
ADJUSTMENT
STEERING LOCK STOPS
Check
1. Measure clearance between tyre wall and radius
arm at full lock. This must be not less than 20
mm, 0.79 in.
Adjust
2. Loosen stop bolt locknut.
3. Turn stop bolt as required.
4. Tighten locknut.
5. Check clearance between tyre wall and radius
arm on each lock.
NOTE: Alternatively lock stop adjustment
may be carried out using following
procedure.
Check
6. Measure stop bolt protrusion A, this must be
59.7 mm, 2.35 in.
Adjust
7. Loosen stop bolt locknut.
8. Turn stop bolt as required.
9. Tighten locknut.
10. Check wheel position at full lock.
FRONT WHEEL ALIGNMENT
Checking Toe-out dimensions
NOTE: Recognised front wheel alignment
and tracking equipment should be used
for this operation. Only the use of basic
equipment is described below. No Adjustment is
provided for castor, camber or swivel pin
inclinations.
1. Set vehicle on level ground with road wheels
positioned straight ahead.
2. Push vehicle back and forwards to settle linkage.
3. Set up the equipment to manufactures
instructions and check alignment as advised by
equipment supplier.
4. Position trammel probes on inner face of wheel,
not the rims, if the latter are damaged.
5. Measure toe-out at horizontal centre-line of
wheels.
6. Check tightness of clamp bolt fixings. Tighten to
14 Nm, 10lbf ft.
STEERING
3
ADJUSTMENT
Adjust
7. Loosen clamps at both ends of track rod.
8. Rotate track rod to increase or decrease its
effective length until correct toe-out is obtained
See GENERAL SPECIFICATION DATA,
Information, Steering.
9. Push vehicle rearwards turning steering wheel
from side to side to settle ball joints. With road
wheels set in straight ahead position, push
vehicle forward a short distance.
10. Recheck track and adjust if necessary.
11. When alignment is correct, tap ball joints in
direction of arrows to maximum of travel, to
ensure full unrestricted movement of track rod.
12. Tighten clamp bolts to 14 Nm, 10 lbf ft.
POWER STEERING BOX - CENTRALISE
Adjust
2. Remove split [cotter] pin from castellated nut
securing drag link to drop arm.
3. Remove castellated nut.
4. Using tool LRT-57-018 release drop arm from
drag link.
5. Turn steering wheel to full RH lock.
6. Turn steering wheel back exactly 2 turns.
7. Fit drop arm to drag link and fit castellated nut.
8. Tighten castellated nut to 40 Nm, 30 lbf ft and
fit new split [cotter] pin.
9. Lower vehicle.
57
STEERING
4
ADJUSTMENT
POWER STEERING SYSTEM - BLEED
Check
1. Position container to collect any fluid spillage.
2. Ensure fluid in reservoir reaches dipstick
maximum.
3. Run engine to normal operating temperature.
4. Recheck and correct reservoir fluid level.
NOTE: During instructions 4 to 6, maintain
maximum fluid level in reservoir. Do not
increase engine speed or move steering
wheel.
5. With engine at idle speed, loosen bleed screw
on steering box. Tighten bleed screw when fluid
emerges.
6. Check fluid level.
7. Fit reservoir cap.
8. Clean away fluid around bleed screw.
9. Check hose connections, pump and steering box
for fluid leaks by holding steering on full lock in
both directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute to avoid overheating fluid and
11. Carry out road test.
STEERING
1
REPAIR
POWER STEERING BOX
General precautions
Whenever any part of the system is removed or
disconnected, utmost cleanliness must be
observed.
Disconnected ports and hoses must be plugged
to prevent ingress of dirt. If metal sediment is
found in system, establish the cause, rectify and
flush system.
Do not start engine until reservoir is full as pump
will be damaged.
Metric pipe fittings are used with O ring pipe
ends on fittings to steering box.
Follow normal O ring replacement procedure
whenever pipes are disconnected.
Ensure compatible metric components are used
when fitting replacement pipes.
CAUTION: After refitting steering linkage
parts, follow correct procedure to ensure
that road wheels, steering box and
steering wheel are correctly positioned relative to
each other when in the straight ahead condition.
NOTE: When drag link is disconnected
from steering box, travel available at
steering wheel to each full lock is not
equal.
Remove
2. Remove panhard rod. See FRONT
SUSPENSION, Repair, panhard rod
3. Remove bolt securing steering damper to drag
link.
4. Release steering damper from drag link.
5. Remove split pin from castellated nut securing
drag link to drop arm.
6. Remove castellated nut.
57
STEERING
2
REPAIR
7. Using tool LRT-57-018 release drop arm from
drag link.
8. Loosen, but do not remove, nut securing tie bar
to mounting arm.
9. Remove 2 bolts securing tie bar to steering box.
10. Move tie bar aside.
12. Lower vehicle.
13. Remove filler cap from power steering fluid
reservoir.
14. Loosen union securing feed pipe to steering box.
15. Disconnect feed pipe from steering box.
16. Loosen union securing return pipe to steering
box.
17. Disconnect return pipe from steering box.
18. Centralise steering. See Adjustment, power
steering box - centralise
19. Remove pinch bolt securing steering column
universal joint to steering box.
20. Loosen pinch bolt securing universal joint to
steering column.
21. Slide universal joint up steering column and
release from steering box.
22. Remove 4 bolts securing steering box to chassis
side member and collect 2 tab washers.
23. With assistance, lower steering box from vehicle
and remove.
Refit
24. Clean mating faces of steering box and chassis
side member.
25. With assistance, position steering box to vehicle,
ensuring locating peg is engaged.
26. Fit bolts and tab washers securing steering box
to chassis and tighten bolts to 80 Nm, 60 lbf ft.
27. Connect steering column to steering box.
28. Tighten universal joint pinch bolts to 25 Nm, 19
lbf ft.
29. Remove plugs from steering box and pipes.
30. Connect feed pipe to steering box and tighten
union to 15 Nm, 11 lbf ft.
31. Connect return pipe to steering box and tighten
union to 20 Nm, 15 lbf ft.
32. Fit fluid reservoir cap.
34. Position tie bar to steering box and loosely fit
bolts and washers.
35. Tighten nut securing tie bar to mounting arm to
80 Nm, 60 lbf ft and then back-off one complete
turn.
36. Tighten bolts securing tie bar to steering box to
81 Nm, 60 lbf ft and then back-off one complete
turn.
37. Fit drop arm to drag link and fit castellated nut.
38. Tighten castellated nut to 40 Nm, 30 lbf ft and
fit new split pin.
39. Connect steering damper to drag link.
40. Fit and tighten bolt securing damper.
41. Fit Panhard rod. See FRONT SUSPENSION,
Repair, panhard rod; Refit
42. Lower vehicle.
43. Bleed power steering system. See Adjustment,
power steering system - bleed
44. Test drive vehicle using both full locks to settle
steering components. If possible, drive vehicle
over uneven ground and include harsh braking.
WARNING: Do not test drive vehicle on
public highway.
45. Drive vehicle in a straight line on level ground
and stop.
46. Tighten nut securing tie bar to mounting to 110
Nm, 81 lbf ft.
47. Tighten bolts securing tie bar to steering box to
81 Nm, 60 lbf ft.
48. Ensure steering wheel is correctly aligned when
wheels are positioned straight ahead.
49. Road test vehicle.
STEERING
3
REPAIR
POWER STEERING FLUID RESERVOIR
Remove
2. Loosen mounting bracket clamp bolt.
3. Raise reservoir from mounting bracket to gain
access to hose clips.
4. Loosen 2 clips securing hoses to fluid reservoir.
5. Disconnect hoses from fluid reservoir.
6. Remove reservoir.
CAUTION: Discard fluid drained from
system. Do not allow fluid to contact paint
work. If spilled, remove fluid and clean
area with warm water.
Refit
7. Position fluid reservoir and connect hoses.
8. Tighten clips securing hoses to fluid reservoir.
9. Fit reservoir to mounting bracket and tighten
clamp bolt to 3 Nm, 2 lbf ft.
10. Bleed power steering system. See power
steering system - bleed
POWER STEERING PUMP
Remove
2. Remove drive belt. See ELECTRICAL, Repair,
4. Using an Allen key to restrain PAS pump pulley,
remove 3 bolts securing pulley to pump.
5. Remove PAS pump pulley.
57
STEERING
4
REPAIR
6. Loosen clip securing PAS hose to pump.
7. Disconnect hose from pump.
8. Loosen union securing PAS pipe to pump.
9. Disconnect PAS pipe from pump.
10. Remove 3 bolts securing PAS pump to engine.
11. Remove PAS pump and collect engine lifting
bracket.
12. Remove 5 bolts securing clamping bracket to
pump.
13. Remove clamping bracket from pump and fit to
new pump.
14. Tighten bolts securing clamping bracket to pump
to 9 Nm, 7 lbf ft.
Refit
15. Clean mating faces of PAS pump and engine.
16. Fit PAS pump and engine lifting bracket to
engine.
17. Fit and tighten bolts securing PAS pump to
engine to 35 Nm, 26 lbf ft.
18. Remove plugs.
19. Connect PAS pipe to pump and tighten union to
20 Nm, 15 lbf ft.
20. Connect PAS hose to pump and secure with clip.
21. Position pulley to PAS pump.
22. Coat threads of PAS pump pulley bolts with
Loctite 242.
23. Restrain pulley using Allen key and tighten bolts
to 10 Nm, 7 lbf ft.
24. Fit drive belt. See ELECTRICAL, Repair,
26. Bleed power steering system. See Adjustment,
power steering system - bleed
STEERING
5
REPAIR
STEERING COLUMN
Remove
1. Loosen clip securing air inlet hose to MAF
sensor.
2. Loosen clip securing air inlet hose to plenum
chamber.
3. Remove air inlet hose.
4. Mark relationship of top universal joint to
steering column and shaft.
5. Remove 2 bolts from top universal joint.
6. Remove steering shaft top universal joint.
7. Remove centre pad from steering wheel.
8. Remove nut securing steering wheel to column
and collect washer.
9. Using tools LRT-57-014 and LRT-57-015,
remove steering wheel from column.
11. Remove instrument panel. See
INSTRUMENTS, Repair, instrument panel
12. Remove 7 screws securing nacelle to steering
column.
13. Remove top half of nacelle.
14. Release bottom half of nacelle from indicator
and light stalk grommets and remove.
15. Remove bolt securing steering column to upper
mounting bracket.
57
STEERING
6
REPAIR
16. Remove 2 lower bolts securing steering column
to body.
17. Remove 2 upper clamping bolts and collect
clamp and rubber.
18. Release harness from clip on column upper
mounting bracket.
19. Release clip from column upper mounting
bracket.
20. Remove 4 bolts securing column upper
mounting bracket.
21. Remove upper mounting bracket.
22. Disconnect 3 multiplugs from rear of switch
pack.
23. Loosen screw and remove switch pack.
24. Disconnect multiplug and 6 Lucars from ignition
switch.
NOTE: Note the positions of the Lucar
connections to the ignition switch.
25. Drill out 2 shear bolts securing ignition barrel to
steering column.
26. Remove ignition barrel and collect washers.
27. Remove brake pedal. See BRAKES, Repair,
brake pedal
28. Remove steering column and upper mounting
bracket from vehicle.
NOTE: The steering column is a non
serviceable component and can only be
replaced as a complete assembly.
Refit
29. Manoeuvre steering column into position in
vehicle.
30. Fit brake pedal. See BRAKES, Repair, brake
pedal
31. Position ignition barrel to steering column and
rotate inner shaft to line up slot with barrel
plunger.
32. Position barrel clamp to steering column and
secure with shear bolts. Evenly tighten bolts, but
do not shear them.
33. Temporarily fit steering wheel and operate
switch and lock mechanism several times to
ensure it functions correctly.
STEERING
7
REPAIR
34. Fully tighten ignition barrel bolts until heads
shear.
35. Connect multiplug and Lucars to ignition barrel.
36. Fit switch pack to steering column and secure
with screw.
37. Connect multiplugs to rear of switch pack.
38. Position column upper mounting bracket and
tighten bolts to 22 Nm, 16 lbf ft.
39. Fit clip to mounting bracket and secure harness.
40. Fit rubber and clamp to upper steering column.
41. Fit clamp bolts and tighten to 22 Nm, 16 lbf ft.
42. Fit lower steering column bolts and tighten to 22
Nm, 16 lbf ft.
43. Fit bolt securing column to upper mounting
bracket and tighten to 22 Nm, 16 lbf ft.
44. Fit lower half of steering column nacelle and
secure to stalk grommets.
45. Fit top half of steering column nacelle.
46. Fit and tighten screws securing nacelle to
steering column.
47. Fit instrument panel. See INSTRUMENTS,
Repair, instrument panel
49. Turn indicator cancelling ring so that slots are
vertical and lug with arrow points to the left.
50. Fit steering wheel with finisher attachment lug at
bottom, ensuring indicator cancelling forks locate
in ring slots.
51. Fit new washer and tighten securing nut to 50
Nm, 37 lbf ft.
52. Fit centre pad to steering wheel.
53. With steering lock engaged, and wheels in
straight ahead position, align assembly marks
and connect steering shaft universal joint to
steering column.
54. Tighten universal joint pinch bolts to 25 Nm, 18
lbf ft.
55. Fit air inlet hose between plenum chamber and
MAF sensor and tighten clips.
STEERING LOWER SHAFT
Remove
1. Set road wheels and steering wheel in straight
ahead position.
2. Loosen clip securing air inlet hose to MAF
sensor.
3. Loosen clip securing air inlet hose to Plenum
chamber.
4. Remove air inlet hose.
5. Mark relationship of steering column inner shaft
to top universal joint.
6. Remove 2 bolts from top universal joint.
7. Remove lower bolt from bottom universal joint.
8. Loosen upper bolt from bottom universal joint.
9. Remove steering shaft and collect universal
joints.
10. Inspect universal joints for wear and excessive
play. Renew if necessary.
11. Inspect universal joints for stiffness. Lubricate if
necessary.
57
STEERING
8
REPAIR
Refit
12. Fit universal joints to steering shaft so pinch
bolts line up with flats on shaft.
13. Fit steering shaft assembly to steering column
and steering box.
14. Align bolt holes with grooves in splines. Fit pinch
bolts and tighten to 25 Nm, 18 lbf ft.
15. Fit air inlet hose between plenum chamber and
MAF sensor.
16. Tighten clips securing hose to plenum chamber
and MAF sensor.
DROP ARM
Remove
2. Remove bolt securing steering damper to drag
link.
3. Disconnect steering damper from drag link.
4. Remove split pin from castellated nut securing
drag link to drop arm.
5. Remove castellated nut securing drag link to
drop arm.
6. Using special tool LRT-57-018, disconnect drag
link from drop arm.
STEERING
9
REPAIR
7. Mark relationship between drop arm and
steering box for reassembly.
8. Bend back tabs on drop arm locking washer.
9. Loosen nut securing drop arm to steering box
but do not remove.
10. Use special tool LRT-57-012 to release drop arm
from steering box spline.
11. Remove nut and discard locking washer.
12. Remove drop arm.
Refit
13. Centralise steering box. See Adjustment,
power steering box - centralise
14. Align reassembly marks and fit drop arm onto
steering box splines.
15. Fit new locking washer and retaining nut to
secure drop arm to steering box. Tighten nut to
175 Nm, 130 lbf ft.
16. Bend over locking washer.
17. Fit drag link to drop arm and tighten castellated
nut to 40 Nm, 30 lbf ft.
18. Fit new split pin to castellated nut.
19. Fit steering damper to drag link.
20. Fit and tighten bolt securing steering damper to
drag link.
21. Lower vehicle.
TRACK ROD
Remove
2. Centralise steering. See Adjustment, power
steering box - centralise
3. Remove 2 bolts securing track rod protection
bracket to differential housing.
4. Remove track rod protection bracket.
57
STEERING
10
REPAIR
5. Remove 2 split pins from castellated nuts
securing track rod to swivel hubs.
6. Remove 2 castellated nuts securing track rod to
swivel hubs.
7. Using special tool LRT-57-018, release track rod
ball joints from swivel hubs.
8. Remove track rod.
9. Loosen 2 clamp bolts securing linkages to track
rod.
10. Remove linkages.
11. Fit new linkages to track rod and loosely tighten
clamp bolts.
12. Screw in linkages to full extent of threads and
fully tighten clamp bolts.
Refit
CAUTION: A track rod that is damaged or
bent must be renewed. DO NOT attempt to
repair or straighten it.
13. Fit track rod and connect to swivel hubs.
14. Fit and tighten castellated nuts to 40 Nm, 30 lbf
ft.
15. Fit new split pins to castellated nuts.
16. Fit track rod protection bracket to differential
housing and tighten bolts.
17. Check wheel alignment. See Adjustment,
front wheel alignment
18. Lower vehicle.
STEERING
11
REPAIR
STEERING DAMPER
Remove
2. Remove 2 nuts securing steering damper to
chassis member and collect washer.
3. Remove nut and bolt securing steering damper
to drag link.
4. Release steering damper from drag link and
chassis member and remove.
Refit
5. Position damper to chassis member and drag
link.
6. Fit bolt and new nut securing damper to drag link
and tighten.
7. Fit washer and nuts securing steering damper to
chassis and tighten.
8. Lower vehicle.
57
STEERING
12
REPAIR
DRAG LINK AND DRAG LINK ENDS
Remove
1. Park vehicle on level ground and chock rear
wheels.
2. Set road wheels in straight ahead position.
3. Raise vehicle and fit axle stands or use a ramp.
4. Remove front road wheel.
5. Disconnect steering damper at drag link bracket.
6. Remove split pin and castellated nut securing
drag link ball joints to swivel housing arms.
7. Disconnect drag link ball joints using
LRT-57-018.
8. Remove drag link.
Remove drag link ends
9. Slacken clamp bolts.
10. Unscrew ball joints and remove from drag link.
11. Clean internal threads of drag link.
Refit drag link ends
12. Fit new ends to drag link and loosely fit clamp
bolts.
13. Set ball joints to drag link measurement to 28,5
mm.
14. Adjust ball pin centres to nominal length of 924
mm, this length is adjusted during refit.
STEERING
13
REPAIR
15. Centralise steering box See Adjustment,
Centralise steering box .
16. Align steering wheel, if necessary.
Refit drag link
CAUTION: A drag link that is damaged or
bent must be renewed. DO NOT attempt to
repair it.
17. Fit drag link to swivel housing arms and tighten
nuts to 40 Nm (30 lbf/ft). Fit new split pins.
18. Ensure full steering travel is obtained between
lock stops See Adjustment, Steering lock
stops. Adjust drag link length to suit.
19. Tap ball joints in direction shown so both pins
are in same angular plane.
20. Tighten clamp bolts to 14 Nm, 10 lbf/ft.
21. Refit road wheel and remove axle stands or
vehicle from ramp.
23. If driving straight ahead and steering wheel is
offset by 0 5in either direction, correct by
adjusting drag link length.
WARNING: To correct steering wheel
deviations greater than 5 remove and
reposition steering wheel See Steering
wheel.
STEERING
1
OVERHAUL
POWER STEERING BOX
WARNING: Wear safety glasses while
removing and refitting circlips and
retaining ring.
CAUTION: Absolute cleanliness is
essential when overhauling the power
steering box.
1. Remove steering box from vehicle. See Repair,
Power Steering Box . Mark drop arm and
steering box for realignment on assembly.
Remove drop arm using extractor LRT-57-012.
Loosen drop arm securing nut, but do not
remove before using extractor. Remove dirt
excluder from output shaft.
2. Drain oil, remove blanking plugs and bleed
screw. Hold steering box over drain tin, turn
input shaft from lock to lock, until oil is drained.
Refit bleed screw.
3. Rotate retainer ring until one end is 12 mm from
extractor hole. Using a drift through hole in
cylinder, lift retaining ring from groove in cylinder
bore.
4. Remove retainer ring, using a screwdriver.
5. Turn input shaft left lock on LH drive, right lock
on RH drive, until piston pushes out cover. Turn
input shaft fully in opposite direction, applying
pressure to piston.
57
STEERING
2
OVERHAUL
6. Remove set screw retaining rack pad adjuster.
7. Remove rack adjuster and pad.
8. Remove sector shaft adjuster locknut.
9. Remove four bolts from sector shaft cover.
10. Screw in sector shaft adjuster until cover is
removed.
NOTE: Sealant is applied to hexagon
socket to tamperproof sector shaft
adjuster.
11. Slide out sector shaft.
12. Remove piston, a bolt screwed into piston will
assist removal.
13. Remove input shaft dirt excluder.
14. Remove worm adjuster locknut using C wrench
LRT-57-007.
15. Remove worm adjuster using wrench
LRT-57-006.
16. Tap splined end of shaft to free bearing.
17. Remove bearing cup and caged ball bearing
assembly.
18. Remove valve and worm assembly.
19. Remove inner bearing cage, cup and shim
washers. Retain shims for reassembly.
NOTE: Should difficulty be experienced,
warm casing and bearing assembly. Cool
bearing cup using a mandrel and tap
steering box on a bench.
STEERING
3
OVERHAUL
Steering box seals
20. Remove circlip and seal from sector shaft
housing bore.
CAUTION: Do not remove sector shaft
bearings from casing. Replacement parts
are not available. If sector shaft bearings
are worn, fit a new steering box.
21. Remove dirt excluder, circlip and seal from input
shaft housing bore.
CAUTION: The use of a seal puller is
recommended to prevent damage to
casing, and possible oil leaks.
INSPECTING
Piston
22. Discard all rubber seals and provide
replacements.
NOTE: A rubber seal is fitted behind
plastic ring on rack piston. Discard seal
and plastic ring.
Steering box casing
23. Examine piston bore for scoring and wear.
24. Examine feed tube.
25. Fit a new feed tube if damaged. Tighten union to
20 Nm, 15 lbf ft .
57
STEERING
4
OVERHAUL
Sector shaft assembly
26. Check there is no side play on roller.
27. If side play on roller exists fit a new sector shaft.
28. Check condition of adjuster screw threads.
Check adjuster end float. Fit new adjuster if end
float exceeds 0.15 mm, 0.006 in.
29. Examine bearing areas on shaft for excessive
wear.
30. Examine gear teeth for uneven or excessive
wear.
Sector shaft cover assembly
31. Inspect cover and bearing. If worn or damaged,
fit a new steering box.
Sector shaft adjuster locknut
32. The locknut is also a fluid seal. Fit new nut at
overhaul.
Valve and worm assembly
33. Examine bearing areas for wear. The areas must
be smooth and not indented.
34. Examine worm track which must be smooth and
not indented.
35. Check for wear on torsion bar assembly pin. No
free movement should exist between input shaft
and torsion bar or between torsion bar and
worm.
NOTE: Any sign of wear makes it essential
to fit new valve and worm assembly.
36. Examine valve rings for cuts, scratches and
grooves. The valve rings should be free to rotate
in grooves.
STEERING
5
OVERHAUL
37. If required, replace all three rings, using ring
expander LRT-57-019. The expander will not
pass over rings already fitted. Remove rings to
allow access without damaging seal grooves.
38. Warm rings and expander tool to aid assembly.
Fit rings to expander, slide expander over valve
and worm assembly. In turn fit rings to their
grooves. Remove expander, slide valve and
worm assembly into ring compressor
LRT-57-020and allow to cool.
Ball bearing and cage assemblies
39. Examine ball races and cups for wear and
general condition.
40. If ball cage has worn against bearing cup, fit
replacements.
41. Bearing balls must be retained by cage.
42. Bearing and cage repair is carried out by
complete replacement of assembly.
Rack thrust pad and adjuster
43. Examine thrust pad for scores.
44. Examine adjuster for wear in pad seat.
45. Fit new sealing ring to rack adjuster.
Rack and piston
46. Examine for excessive wear on rack teeth.
47. Ensure thrust pad bearing surface is free from
scores and wear.
48. Ensure piston outer diameters are free from
burrs and damage.
49. Examine seal and ring groove for scores and
damage.
50. Fit new ring to piston. Warm nylon seal and fit to
piston.
51. Slide piston assembly into cylinder with rack
tube outwards.
57
STEERING
6
OVERHAUL
Reassemble
NOTE: When fitting replacement oil seals
lubricate with recommended fluid and
ensure absolute cleanliness.
Sector shaft oil seal
52. Fit oil seal, lip side first.
53. Fit extrusion washer.
54. Fit dust seal, lipped side last.
55. Fit circlip.
Fitting valve and worm assembly
56. Refit original shims and inner bearing cup. Use
Petroleum Jelly to aid assembly.
NOTE: If original shims are not used, fit
shims of 0.76 mm, 0.030 in thickness.
57. Fit inner cage and bearings assembly.
58. Fit valve and worm assembly.
59. Fit outer cage and bearings assembly.
60. Fit outer bearing cup.
61. Fit new worm adjuster sealing ring.
STEERING
7
OVERHAUL
62. Loosely screw adjuster into casing.
63. Fit locknut, do not tighten.
64. Turn in worm adjuster until end float is almost
eliminated. Ensure bearing cages are seated
correctly.
65. Measure maximum rolling torque of valve and
worm assembly, using a torque wrench and
spline socket LRT-57-025.
66. Turn in worm adjuster while rotating shaft to
increase figure measured in instruction 65. to
0.56 Nm, 0.41 lbf ft.
67. Back off worm adjuster 1/4 turn. Turn in worm
adjuster to increase reading at 14 by 0.21 - 0.34
Nm, 0.15 - 0.25 lbf ft with locknut tight, 100 Nm
74 lbf ft . Use worm adjusting wrench
LRT-57-006and locknut wrench LRT-57-028.
Fitting rack and piston
68. Screw slave bolt into piston to aid assembly.
69. Fit piston and rack so piston is 70 mm, 2.75 in
from outer end of bore.
Fitting sector shaft
70. Fit sector shaft using seal saver LRT-57-021.
Align roller with cut out in casing. Push in sector
shaft while rotating input shaft to allow sector
roller to engage worm.
57
STEERING
8
OVERHAUL
Fitting rack adjuster
71. Fit rack adjuster and thrust pad to engage rack.
Back off half turn on adjuster.
72. Loosely fit new nylon pad and adjuster set screw
assembly.
Fitting sector shaft cover
73. Fit new sealing ring to cover.
74. Align cover with casing.
75. Screw cover assembly fully on to sector shaft
adjuster screw.
76. If necessary back off sector shaft adjuster screw.
Tap cover in place to allow cover to joint fully
with casing.
NOTE: Before tightening fixings, rotate
input shaft to ensure sector shaft roller is
free to move in valve worm. If initial
resistance is left, turn adjuster screw
approximately two turns in a clockwise direction.
77. Fit cover bolts. Tighten to75 Nm, 55 lbf ft .
Fitting cylinder cover
78. Fit new square section seal to cover.
79. Remove slave bolt fitted at instruction 68. Press
cover into cylinder just to clear retainer ring
groove.
80. Fit retaining ring to groove with one end of ring
positioned 12 mm, 0.472 in from extractor hole.
STEERING
9
OVERHAUL
Adjusting sector shaft
NOTE: Refit drop arm and tighten nut
sufficiently to ensure that no backlash
exists between drop arm and sector shaft.
81. To set worm on centre, rotate input shaft to full
inner-lock full right lock for a left hand drive
vehicle, full left lock for a right hand drive
vehicle. Rotate input shaft back towards centre
two full turns.
82. The box is now on centre and can be adjusted.
83. Hold input shaft and rock drop arm to establish
backlash is present. Continue rocking and slowly
turn sector shaft adjusting screw clockwise.
Continue rotating adjuster screw until backlash
has almost been eliminated.
84. Refit locknut and tighten.
NOTE: It is important steering box is
centralised before any adjustments are
made.
85. Check maximum rolling torque one and a quarter
turns either side of centre position, using a
torque wrench and spline socket LRT-57-025.
Rotate adjuster screw to obtain across centre
torque of 0.34 Nm, 0.25 lbf ft plus torque figure
at one and a quarter turns. Tighten adjuster
locknut to 60 Nm, 44 lbf ft .
Adjusting rack adjuster.
86. Turn in rack adjuster to increase figure
measured in instruction 34. by 0.23 - 0.34 Nm,
0.17 - 0.25 lbf ft.
The final figure may be less, but must not
exceed 1.35 Nm, 1.0 lbf ft.
87. Lock rack adjuster in position with grub screw.
Tighten to 5 Nm, 4 lbf ft .
Torque peak check
With input shaft rotated from lock to lock, rolling
torque figures should be greatest across centre
position and equally disposed about centre position.
The condition depends on value of shimming fitted
between valve and worm assembly inner bearing cup
and casing. The original shim washer value will give
correct torque peak position unless major components
have been replaced.
88. With input coupling shaft toward the operator,
turn shaft fully counter-clockwise.
89. Check torque figures obtained from lock to lock
using torque wrench and spline socket
LRT-57-025.
90. Check also for equal engagement either side of
centre.
57
STEERING
10
OVERHAUL
Adjustments
91. Note where greatest figures are recorded
relative to steering position. If greatest figures
are not recorded across centre of travel (steering
straight-ahead), adjust as follows:
If torque peak occurs before centre position, add to
shim washer value; if torque peak occurs after centre
position, subtract from shim washer value, refer to
fitting valve and worm assembly .
Shim washers are available as follows:
0.03mm, 0.07mm, 0.12mm and 0.24mm
0.001in, 0.003in, 0.004in and 0.008in.
NOTE: Adjustment of 0.07mm, 0.003 in to
shim value will move torque peak area by
1/4 turn on the shaft.
CAUTION: When reshimming valve and
worm, extreme caution must be exercised
to prevent seal damage during
reassembly.
Input shaft oil seal
92. Fit seal, lip side first, into housing. Use seal
saver LRT-57-016and seal installer LRT-57-026.
Note that seal is fitted to a depth of 4.75 - 5.00
mm, 0.19 - 0.20 in from face of box.
93. Secure seal with circlip.
94. Smear inner lip of dirt excluder with grease. Fit
dirt excluder using LRT-57-027. When fitted
correctly outer shoulder of excluder is 4.00 - 4.50
mm, 0.16 - 0.18 in from face of box, dimension
X.
95. Remove drop arm. Smear inner lip of dirt
excluder with PTFE grease and refit, ensuring
outer lip is flush with casing.
96. With input shaft on centre, align assembly marks
on drop arm and steering box. Fit drop arm to
steering box using a new tab washer. Tighten
nut to 175 Nm, 130 lbf ft, bend over tab.
97. Fit steering box See Repair, Power Steering
Box .
STEERING
1
TORQUE VALUES
Nm lbf ft
Drag link to drop arm 40 ........................................................ 30
Ball joint nuts 40 .................................................................... 30
Clamp bolt nuts 14 ................................................................ 10
Steering column bracket nuts 22 ........................................... 16
Steering wheel nut 50 ........................................................... 37
Tie bar to mounting nut 110 .................................................... 80
Universal joint pinch bolt 25 .................................................. 18
PAS box Adjuster locknut 60 ....................................................... 45
Drop arm nut 175 ........................................................... 130
Sector shaft cover to steering box 75 ........................... 55
Steering box to chassis 80 ........................................... 60
Steering box fluid pipes 14mm thread 15 ..................... 11
Steering box fluid pipes 16mm thread 20 ..................... 15
Tie bar 80 ..................................................................... 60
Adjuster grub screw 5 ................................................ 4
PAS pump High pressure fluid pipe 20 .......................................... 15
Power steering pump mounting 35 .............................. 25
Pulley bolts, power steering pump 10 .......................... 7
Hose clamp 3 ............................................................. 2
Front clamping bracket bolts 9 ................................... 7 PAS reservoir
Hose clamp 3 ............................................................. 2
The following Torque values are for screws and bolts that are not specified on previous page.
METRIC Nm lbf ft
M5 6 ........................................................................... 4.5
M6 9 ........................................................................... 7
M8 25 ........................................................................... 18
M10 45 ......................................................................... 33
M12 90 ......................................................................... 65
M14 105 ......................................................................... 77
M16 180 ......................................................................... 133
UNC / UNF 1/4 9 ........................................................................... 7
5/16 24 ......................................................................... 18
3/8 39 ........................................................................... 29
7/16 78 ......................................................................... 58
1/2 90 ........................................................................... 65
5/8 135 ........................................................................... 100
FRONT SUSPENSION
1
DESCRIPTION
The front suspension design allows maximum wheel
travel and axle articulation providing good ground
clearance without loss of traction or directional
stability. A wheel speed sensor is attached to each
swivel housing with a reluctor ring on the constant
velocity joints. The input from the wheel sensors are
used by the engine management ECM for Off-road
detection.
Long radius arms are fitted to the front axle and
provide maximum axle articulation which is vital for off
road performance. The radius arms are secured to
fabricated mounting brackets welded to the front axle.
Flexible rubber bushes are used on a stem end joint
to secure the rear of the radius arms to mountings on
the chassis cross member.
A panhard rod, which ensures that the front axle
remains centrally located, is fitted transversely and
also uses ferrule rubber bush mountings at both axle
and chassis locations.
Two rubber bearing bushes, with retaining straps,
secure the rear of the anti-roll bar to the chassis
mountings, while bushed links support the front of the
bar to the front axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement
in all conditions. The shock absorbers are secured to
fabricated towers which are bolted to the chassis. The
upper and lower fixings use a single location stud with
flexible rubber bushes, support washers and securing
nuts. Retaining plates are used to secure the coil
springs to the fabricated towers and axle mountings.
Rubber bump stops are fitted underneath the chassis,
adjacent to the front road springs, and prevent
possible damage that could occur should there be
excessive axle to chassis movement.
Front suspension
1. Panhard rod
2. Radius arms
3. Coil springs
4. Shock absorber
5. Anti-roll [sway] bar
FRONT SUSPENSION
1
REPAIR
SELF LOCKING NUTS
WARNING: Where self locking nuts are
removed, they must be replaced with new
nuts of same specification.
ANTI-ROLL [SWAY] BAR
Remove
2. Mark anti-roll [sway] bar rubber bushes for
reassembly.
3. Remove 4 nuts and bolts securing anti-roll
[sway] bar to mounting brackets.
4. Remove 2 nuts and bolts securing anti-roll
[sway] bar to ball joint links.
5. Remove anti-roll [sway] bar.
6. Remove rubber bushes from anti-roll [sway] bar.
Refit
7. Fit bushes to anti-roll [sway] bar. Ensure split in
bushes points towards axle on RH side, and
away from axle on LH side.
8. Position anti-roll [sway] bar and loosely fit nuts
and bolts to mounting brackets.
NOTE: Angled sides of bar should point
downwards.
9. Using new nuts, fit anti-roll [sway] bar to ball joint
links. Tighten to 68 Nm, 50 lbf ft.
10. Tighten nuts and bolts securing anti-roll [sway]
bar to mounting brackets to 30 Nm, 22 lbf ft.
11. Lower vehicle.
60
FRONT SUSPENSION
2
REPAIR
ANTI-ROLL [SWAY] BAR BALL JOINT LINKS
Remove
2. Remove 2 nuts and bolts securing ball joint links
to anti-roll [sway] bar and collect washers and
rubber bushes.
3. Release ball joints using special tool
LRT-57-018.
4. Remove 2 split pins from castellated nuts.
5. Remove 2 castellated nuts.
6. Remove ball joint links.
Refit
7. Fit ball joint links, ensuring they point upwards.
8. Fit castellated nuts and tighten to 40 Nm, 30 lbf
ft.
9. Fit split pins to castellated nuts.
10. Align anti-roll [sway] bar to ball joint links.
11. Fit bolts, washers, rubber bushes, and new lock
nuts securing anti-roll [sway] bar to ball joint
links. Tighten bolts to 68 Nm, 50 lbf ft.
12. Lower vehicle.
PANHARD ROD
Remove
2. Remove bolt securing Panhard rod to mounting
arm and collect nut
3. Remove bolt securing Panhard rod to axle
bracket and collect nut.
4. Remove Panhard rod.
5. Press out flexible bushes.
CAUTION: Ensure pressure is exerted on
outer edge of bush, not rubber inner.
6. Fit replacement bushes.
Refit
7. Position Panhard rod to axle bracket and
mounting arm.
8. Fit nut and bolt securing Panhard rod to axle
bracket and tighten to 88 Nm, 65 lbf ft.
9. Fit nut and bolt securing Panhard rod to
mounting arm and tighten to 88 Nm, 65 lbf ft.
10. Lower vehicle.
FRONT SUSPENSION
3
REPAIR
RADIUS ARM
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Raise front of vehicle and support axle.
4. Remove nut securing radius arm to chassis side
member and collect washer and rubber bush.
5. Remove 2 bolts securing radius arm to axle and
collect nuts.
6. Remove split [cotter] pin from castellated nut
securing track rod to swivel hub.
7. Remove castellated nut securing track rod to
swivel hub.
8. Using special tool LRT-57-018release track rod
from swivel hub.
9. Move track rod aside.
10. Lower front of radius arm to clear axle and
remove from vehicle.
11. Press out bushes from radius arm.
CAUTION: Ensure pressure is exerted on
outer edge of bushes, and not rubber
inner.
12. Press in replacement bushes.
Refit
13. Position radius arm to vehicle.
14. Loosely fit bolts securing radius arm to axle.
15. Connect track rod to swivel hub.
16. Fit and tighten castellated nut securing track rod
to swivel hub to 40 Nm, 30 lbf ft.
17. Fit new split [cotter] pin to castellated nut.
18. Tighten nuts securing radius arm to axle to 197
Nm, 145 lbf ft.
19. Fit rubber bush and washer to radius arm.
20. Fit and tighten nut securing radius arm to
chassis member to 175 Nm, 130 lbf ft.
21. Remove jack from under axle.
22. Fit road wheel.
23. Remove stand(s) and lower vehicle.
60
FRONT SUSPENSION
4
REPAIR
FRONT SHOCK ABSORBER
Remove
1. Loosen road wheel retaining nuts.
2. Support chassis on stands and remove road
wheel.
3. Support axle weight with jack.
4. Remove shock absorber lower fixing and
withdraw cupwasher, rubber bush and seating
washer.
5. Remove four shock absorber bracket fixings.
6. Withdraw shock absorber and bracket complete.
7. Withdraw lower seating washer, rubber bush and
cupwasher.
8. Remove fixings, shock absorber to mounting
bracket.
9. Withdraw mounting bracket.
10. Lift off top seating washer, rubber bush and
cupwasher.
Refit
11. Assemble shock absorber components.
12. Position shock absorber, complete with bracket
and secure with 4 fixings.
13. Secure shock absorber lower fixing.
14. Fit road wheel, remove chassis stands and jack.
FRONT SUSPENSION
5
REPAIR
FRONT ROAD SPRING
Remove
1. Remove front shock absorber. See Front
shock absorber
CAUTION: Avoid over stretching brake
hoses. If necessary loosen hose connector
locknuts to allow hoses to follow axle.
2. Lower axle sufficient to free road spring.
3. Withdraw road spring.
4. Withdraw shock absorber bracket securing ring.
Refit
5. Fit shock absorber bracket retaining ring. Retain
in position with a nut.
6. Position road spring and raise axle.
7. Remove nut retaining securing ring.
8. Fit front shock absorber. See Front shock
absorber
BUMP STOP
Remove
1. Remove fixings.
2. Remove bump stop.
Refit
3. Position bolts in slots in chassis brackets.
4. Fit bump stop, secure with washers and nuts.
FRONT SUSPENSION
1
TORQUE VALUES
Nm lbf ft
Anti-roll bar front:
- Mounting brackets 30 ...................................................... 22
- Ball link self lock nut 70 ................................................... 50
- Castellated nut 40 ........................................................... 30
Drag link to axle 40 ............................................................... 30
Securing ring for mounting turret 14 ...................................... 10
Radius arm to chassis 175 ...................................................... 130
Panhard rod mounting arm to chassis 90 ............................. 65
Panhard rod to axle 90 .......................................................... 65
Panhard rod to mounting arm 90 .......................................... 65
Tie bar to Panhard rod 110 ..................................................... 80
Radius arm to axle 200 ........................................................... 150
Road wheel nuts 130 .............................................................. 95
REAR SUSPENSION
1
DESCRIPTION
The rear suspension locates the rear axle with two
round section steel lower link arms and a forged A
frame upper link assembly. This system allows
maximum axle articulation and wheel travel while
maintaining roll stiffness and directional stability.
The link arm is secured by a single retaining nut to the
chassis mounting, comprising a rubber bushed
bracket, which is retained by three fixings. A ferrule
rubber bush with a single retaining bolt is used to
secure the link arm to its axle mounting.
The upper link assembly is located on the rear
differential housing by a pivot ball-pin assembly. Two
brackets, bolted to the chassis crossmember,
support both sides of the A frame of the link
assembly, secured by single retaining bolts.
Two rubber bearing bushes with retaining straps,
secure the rear of the anti-roll bar, if fitted, to the
chassis mountings, while bushed links support the
front of the anti-roll [sway] bar to the axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement.
The shock absorbers are secured to chassis mounting
brackets and fabricated lower mountings welded to to
the rear axle. Retaining plates are used to secure the
coil springs to the axle mounting while fabricated
brackets, welded to to the chassis, are used for the
upper spring location.
Rear axle suspension
1. A frame, upper link assembly
2. Lower link
3. Coil springs
4. Shock absorber
REAR SUSPENSION
1
REPAIR
REAR ROAD SPRING
Remove
1. Loosen rear road wheel retaining nuts.
2. Support chassis on stands and remove wheels.
3. Support rear axle weight with jack.
4. Disconnect shock absorbers at one end.
5. Position coil spring compressor correctly on road
spring.
6. Compress spring evenly to facilitate removal.
7. Lower axle to free road spring from upper seat.
CAUTION: Avoid lowering axle further than
rear brake flexible hose and road speed
sensor leads will allow.
8. Remove spring retainer plate.
9. Withdraw road spring.
10. Collect off spring seat.
Refit
11. Position spring seat on axle location.
12. Fit road spring into chassis location and using a
turning motion, fit to spring seat.
13. Fit spring retainer plate.
14. Secure shock absorber. Tighten to 37 Nm, 27
lbf ft
15. Fit road wheels. Tighten to 130 Nm, 95 lbf ft.
16. Remove chassis stands and jack.
REAR SHOCK ABSORBER
Remove
1. Loosen road wheel retaining nuts.
2. Support chassis on stands. Remove road wheel
and support rear axle weight with jack.
3. Remove fixings and withdraw shock absorber
from axle bracket.
4. Remove upper fixings.
5. Withdraw shock absorber.
6. If required remove mounting bracket
7. If required remove mounting rubbers.
Refit
8. Position shock absorber and fit upper fixings.
9. Secure shock absorber with lower fixings to axle
bracket. Tighten to 37 Nm, 27 lbf ft.
10. Fit road wheels. Tighten to 130 Nm, 95 lbf ft.
11. Remove chassis stands and jack.
64
REAR SUSPENSION
2
REPAIR
SUSPENSION LINK - UPPER
Remove
1. Support rear of chassis on stands, allow axle to
hang freely.
2. Remove fixings, upper link bracket to frame.
3. Remove fixings, upper links to pivot bracket.
4. Remove upper link complete with frame bracket.
5. Remove bolt.
6. Separate link from bracket.
Renew bush
7. Press out rubber bushes.
8. Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
Refit
NOTE: Do no fully tighten fixings until all
components are in position.
9. Secure link to frame bracket.
10. Fit upper link to pivot bracket.
11. Fit frame bracket to chassis mounting.
12. Fully tighten fixings to correct torque. See
Specifications, torque, Torque values.
REAR SUSPENSION
3
REPAIR
SUSPENSION LINK - LOWER
Remove
1. Site vehicle on a ramp [hoist].
2. Alternatively, support vehicle on stands under
rear axle.
3. Remove lower link rear fixings.
4. Remove mounting bracket fixings at side
member bracket.
5. Remove lower link complete.
6. Remove locknut.
7. Remove mounting bracket from lower link.
Renew bush
8. Press out rubber bushes.
9. Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
Refit
10. Fit mounting rubber to lowerlink.
11. Secure mounting rubber to chassis bracket, but
do not fully tighten locknut.
12. Fit lower link to axle mounting and secure fixing
13. Lower vehicle, allow axle to take up static laden
position, and fully tighten link chassis fixing to
175 Nm, 130 lbf ft.
64
REAR SUSPENSION
4
REPAIR
ANTI-ROLL [SWAY] BAR
Remove
1. Note for reassembly, position of rubber bushes
on anti-roll [sway] bar.
2. Remove 4 nuts, bolts and washers securing 2
bush straps to chassis mountings.
3. Remove nuts, bolts, washers and rubber bushes
from the ball joint links.
4. Remove anti-roll [sway] bar.
Refit
5. Position rubber bushes on anti-roll [sway] bar. Fit
joint towards axle.
6. Fit anti-roll [sway] bar with 2 straps. Ensure ball
joint link arms point down as shown in J6259.
Loosely fit, bolts, washers and NEW nyloc nuts.
7. Fit bolt, washers and rubber bushes. Fit anti-roll
[sway] bar to ball joint links and tighten to 68Nm,
50 lbf ft .
8. Tighten nuts securing straps to 30Nm, 22 lbf ft.
REAR SUSPENSION
5
REPAIR
ANTI-ROLL [SWAY] BAR BALL JOINT LINKS
Remove
1. Remove 2 nuts, bolts, washers and rubber
bushes from ball joint links and lower anti-roll
[sway] bar to clear links.
2. Remove cotter pin and loosen castellated nut a
few turns.
3. Release ball joint using special tool 18G
1063Aas shown.
4. Remove castellated nut and ball joint link.
Refit
5. Fit ball joint link arm and castellated nut. Point
ball joint link arm down as shown. Tighten fixing
to 40 Nm, 30 lbf ft and fit new cotter pin.
6. Align anti-roll bar to ball joint links.
7. Fit bolts, washers and rubber bushes using new
self locking nuts and secure anti-roll [sway] bar
to ball joint links. Tighten to 68Nm, 50 lbf ft .
REAR SUSPENSION
1
TORQUE VALUES
Rear Suspension
Nm lbf ft
Anti-roll [sway] bar:
- Strap nyloc nuts 30 .................................................... 22
- Ball link self lock nut 68 .............................................. 50
- Castellated nut 40 ...................................................... 30
Top link to mounting bracket 175 ............................................ 130
Bottom link to axle 175 ............................................................ 130
Bottom link to chassis 175 ...................................................... 130
Top link bracket to rear cross member 47 ............................. 35
Shock absorber to axle 37 .................................................... 27
Road wheel nuts 130 .............................................................. 95
BRAKES
1
DESCRIPTION
The mechanical components of the hydraulic braking
system consist of four piston caliper disc brakes at the
front and two piston caliper disc brakes at the rear.
The front brake discs are vented.
A cable controlled parking brake operates a single
drum brake mounted on the rear output shaft of the
transfer gearbox and is completely independent of the
main braking system.
The basic hydraulic system involves 2 separate and
independent primary and secondary circuits which
permits a degree of braking should a fault occur in
one of the circuits. The primary circuit operates the
rear brake calipers and the secondary circuit the front
brake calipers.
Master cylinder
A tandem master cylinder, which is assisted by a
lightweight compact servo, is fed by a divided fluid
reservoir. The rear section supplies fluid for the
primary circuit and the front section the secondary
circuit.
Master cylinder components
1. Secondary plunger
2. Secondary spring
3. Recuperation seal - secondary
4. Primary spring
5. Recuperation seal - primary
6. Primary plunger
70
BRAKES
2
When the brakes are off, the fluid can move
unrestricted between the dual line system and the
separate reservoirs in the fluid supply tank. When the
footbrake is applied, the primary plunger assembly
moves up the cylinder bore and the pressure created
acts in conjunction with the primary spring to
overcome the secondary springs, thus moving the
secondary plunger assembly up the bore at the same
time. Initial movement of both plungers takes the
recuperating seals past the cut-off holes in the
cylinder chambers A and C, and applies pressure to
the fliud in those chambers, which is directed to the
respective cylinders of each of the separate circuits.
The fluid in chambers B and D is unaffected by
movement of the plungers and can move unrestricted
between the separate chambers and respective
reservoirs in the fluid supply tank, both before and
during brake application. When the brakes are
released, the plunger assemblies, aided by the return
springs are retracted faster than the fluid; this creates
a depression between the fluid in chambers A and C
and the recuperation seals.
The recuperation seals momentarily collapse allowing
fluid in chambers B and D, which is unaffected by
the movement of the plungers, to flow through the
holes in the plungers, over the collapsed seals and
into chambers A and C respectively. The movement
of fluid from one set of chambers to the other, is
compensated for by fluid from the separate reservoirs
in the supply tank moving through the feed holes in
the cylinder. Conversely, the final return movement of
the plunger assemblies causes the extra fluid in
chambers A and C to move through the cut off holes
into the fluid reservoir.
The servo unit provides controlled power assistance
to to the brake pedal when pressure is applied.
Vacuum is obtained from the depression in the inlet
manifold. The vacuum is applied to both sides of a
flexing diaphragm and by admitting atmosheric
pressure to the rear diaphragm, assistance is
obtained. The servo unit is mounted between the
brake pedal and master cylinder and is linked to these
by push rods. Should a vacuum failure occur, the two
push rods will act as a single rod allowing the brakes
to function in the normal way, although more effort will
be required to operate the brake pedal.
BRAKES
3
Hydraulic system
A brake fluid loss switch is fitted to the master cylinder
reservoir filler cap. The switch is wired to a warning
light on the vehicle fascia and will illuminate
momentarily when ignition is switched on and
indicates that the warning circuit is functioning
correctly. A hydraulic failure in the system will result in
fluid loss, causing the warning light to illuminate.
A pressure reducing valve (PRV), fitted to the RH
bulkhead in the engine compartment, maintains the
braking balance, see J6322. Pressure to the rear
calipers is regulated by the PRV, this valve is of the
failure by-pass type allowing full system pressure to
the rear brake calipers in the event of a front
(secondary) circuit failure.
A. Primary circuit
B. Secondary circuit
C. Pressure reducing valve (PRV)
1. LH rear brake caliper
2. T-connector
3. RH rear brake caliper
4. Brake servo
5. Master cylinder and reservoir
6. LH front brake caliper
7. RH front brake caliper
BRAKES
1
REPAIR
GENERAL BRAKE SERVICE PRACTICE
Brake fluid precautions
WARNING: Do not allow brake fluid to
come into contact with eyes or skin.
CAUTION: Brake fluid can damage
paintwork, if spilled wash off immediately
with plenty of clean water.
CAUTION: Use only correct grade of brake
fluid. If an assembly fluid is required use
ONLY brake fluid. Do NOT use mineral oil,
i.e. engine oil etc.
CAUTION: Thoroughly clean all brake
calipers, pipes and fittings before
commencing work on any part of the brake
system. Failure to do so could cause foreign
matter to enter the system and cause damage to
seals and pistons which will seriously impair the
efficiency of the brake system. To ensure the
brake system efficiency is not impaired the
following warnings must be adhered to :-
DO NOT use any petroleum based cleaning
fluids or any proprietary fluids containing
petrol.
DO NOT use brake fluid previously bled from
the system.
DO NOT flush the brake system with any fluid
other than the recommended brake fluid.
The brake system should be drained and flushed
at the recommended service intervals.
Cover all electrical terminals carefully to make
absolutely certain that no fluid enters the
terminals and plugs.
FLUID LEVEL CHECK / TOP-UP
WARNING: Clean reservoir body and filler
cap before removing cap. Use only fluid
from a sealed container.
1. Park vehicle on level ground.
2. Check level is between MIN and MAX marks.
3. If level is below MIN mark top up fluid level to
MAX mark on reservoir, using correct fluid. See
Information, Brake fluid reservoir
CAUTION: Do not fill reservoir above
maximum line.
70
BRAKES
2
REPAIR
BRAKE SYSTEM BLEED
Preparation
WARNING: Before bleeding the brake
system refer to general brake service
practice. See General Brake Service
Practice
During bleed procedure, brake fluid level must not
be allowed to fall below the MIN level. Keep
reservoir topped to the MAX level.
To bleed the hydraulic circuits, four bleed nipples
are provided, one at each caliper.
There are two methods by which air can be
removed from the braking system:-
1. MANUAL BLEED PROCEDURE.
2. PRESSURE BLEED PROCEDURE.
Pressure bleed procedure
Purpose designed equipment for pressure filling and
bleeding of hydraulic systems may be used on Land
Rover vehicles. The equipment manufacturers
instructions must be followed and the pressure must
not exceed 4.5 bar, 65 lbf/in
2
.
Manual bleed procedure
Equipment required
Clean glass receptacle
Bleed hose
Wrench
Approx 2 litres brake fluid See LUBRICANTS,
Master cylinder bleed
1. Disconnect battery.
2. Depress brake pedal fully and slowly 5 times.
3. Release the pedal and wait for ten seconds.
4. Air bubbles will rise into the reservoir during
these instructions.
5. Repeat instructions until a firm resistance is felt
at the pedal.
Complete circuit bleed
1. Fit bleed hose to any caliper bleed screw.
2. Dip free end of bleed hose into brake fluid in
bleed bottle.
3. Open bleed screw of caliper.
4. Depress brake pedal fully several times until fluid
is clear of air bubbles.
5. Keeping pedal fully depressed, tighten bleed
screw, then release pedal.
6. Repeat the above procedure on remaining 3
calipers.
7. Fit all bleed screw protection caps.
8. Check/top-up fluid level when bleeding is
complete. See Fluid Level Check / Top-Up
BRAKES
3
REPAIR
MASTER CYLINDER
Before starting repair refer to general brake service
practice See General Brake Service Practice
Remove
2. Place a container under the master cylinder to
catch escaping brake fluid.
3. Clean area round master cylinder ports.
4. Disconnect pipes from master cylinder ports.
Cover, not plug, the pipe ends to prevent entry of
dirt.
5. Disconnect electrical leads from reservoir cap.
6. Remove two nuts securing master cylinder to
servo and withdraw cylinder.
7. Remove reservoir cap and drain fluid into
suitable container for disposal.
8. The reservoir is a push fit in the master cylinder
and secured by seals. Carefully ease the
reservoir from the master cylinder by rolling it
from the seals. Note that the two seals are
different in size.
Refit
9. Insert new reservoir seals in the master cylinder
ports and fit reservoir to master cylinder.
10. Ensuring that water ingress seal is in position, fit
master cylinder to servo. Tighten fixings to 26
Nm, 19 lbf/ft.
11. Connect brake pipes to master cylinder ports
and tighten to 15 Nm, 11 lbf/ft.
12. Fit electrical leads to reservoir cap
13. Fill reservoir with recommended brake fluid. See
Information, Recommended lubricants and
fluids
14. Bleed the brake system See Brake system
bleed
15. Reconnect battery and road test vehicle.
70
BRAKES
4
REPAIR
PRESSURE REDUCING VALVE (PRV)
Remove
2. Clean reducing valve parts.
3. Place a container under PRV valve to catch
escaping brake fluid.
4. Disconnect primary circuit pipe unions A
from PRV.
5. Disconnect secondary circuit pipe unions B
from PRV.
6. Cover pipes to prevent ingress of dirt.
7. Remove single retaining nut and bolt securing
PRV to engine bulkhead.
8. Remove valve.
Refit
9. Fit valve to engine bulkhead. Tighten bolt to 15
Nm, 11 lbf/ft.
10. Connect primary and secondary circuit pipes to
PRV. Tighten to 16 Nm, 12 lbf/ft.
11. Fill brake reservoir with recommended brake
fluid. See LUBRICANTS, FLUIDS AND
12. Bleed the brake system. See Brake system
bleed
13. Reconnect battery and road test vehicle.
SERVO NON RETURN VALVE
Remove
1. Disconnect brake vacuum hose from servo
non-return valve.
2. Carefully prise valve out with a screwdriver blade
between valve and grommet. Take care not to
exert too much pressure on the vacuum
chamber.
3. Remove rubber grommet but be careful not to
allow it to fall into the vacuum chamber.
4. Check the valve for correct operation; it should
not be possible to pass air through into the servo
in direction of arrow.
WARNING: Do not use compressed air.
Refit
5. Fit rubber grommet.
6. Smear ribs of the valve with Lucas Girling
grease to assist assembly, and push valve fully
home.
7. Connect vacuum hose to the valve.
BRAKES
5
REPAIR
SERVO ASSEMBLY
Remove
practice. See General Brake Service Practice
NOTE: The non-return valve and grommet,
are the only serviceable components, in
event of failure or damage, fit a new unit.
1. Remove master cylinder. See Master cylinder
2. Disconnect vacuum supply hose from servo unit.
3. At footwell, release 2 brake pedal return springs.
4. Disconnect leads from brake light switch at rear
of pedal box.
5. Remove blanking grommets from each side of
pedal box.
6. Remove split pin and clevis pin securing servo
push rod to brake pedal.
7. Remove 4 nuts and plain washers securing
servo to pedal box.
8. Remove servo assembly and rubber washer
from bulkhead.
Refit
9. Locate servo assembly and rubber washer to
engine bulkhead and secure to pedal box.
Tighten fixings to 14 Nm, 10 lbf/ft.
10. Fit brake pedal to servo push rod with clevis pin
and new split pin.
11. Fit blanking grommets to each side of pedal box.
12. At footwell, attach pedal return springs.
13. Connect vacuum hose to servo non-return valve.
14. Fit brake master cylinder to servo unit. See
master cylinder
70
BRAKES
6
REPAIR
BRAKE PEDAL
Service repair no - 70.35.01 - Brake pedal
Service repair no - 70.35.03 - Pedal box
Remove
1. Remove brake servo assembly. See Brake
servo assembly
2. Remove 6 bolts securing pedal box to engine
bulkhead.
3. Taking care not damage brake fluid pipes,
remove pedal box assembly and gasket.
4. Release return springs from pedal and pedal box
bosses.
5. Using a suitable punch, drift out retaining pin and
withdraw pedal pivot shaft.
6. Remove brake pedal complete with pivot
bushes.
7. Examine components for wear or damage,
renew as necessary.
8. If it is necessary to fit new pivot bushes, they
must be reamed out to 15,87 mm 0,02 mm,
0.625 0.001 in after fitment.
Refit
9. Lubricate pedal pivot shaft and bushes with
general purpose grease.
10. Fit pedal to pedal box, insert pivot shaft and
secure with new split pin.
11. Attach return springs to pedal and pedal box
bosses.
12. Fit pedal box and gasket to engine bulkhead.
Tighten fixings to 25 Nm, 18 lbf/ft.
13. Fit brake servo assembly. See Brake servo
assembly
BRAKES
7
REPAIR
FRONT BRAKE PADS
Remove
1. Remove front road wheels .
2. Clean exterior of calipers.
3. Remove split [cotter] pin from retaining pins.
4. Remove pad retaining pins and anti-rattle
springs.
5. Remove brake pads.
6. Clean exposed parts of pistons, using new brake
fluid. Wipe away excess with a lint free cloth.
7. Using piston clamp LRT-70-500press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
8. Fit brake pads.
9. Fit pad retaining pins and anti-rattle springs.
Secure with new split [cotter] pins.
10. Apply service brake pedal several times to locate
pads.
11. Check fluid reservoir. Top-up if necessary, using
correct grade of fluid. See LUBRICANTS,
70
BRAKES
8
REPAIR
REAR BRAKE PADS
Remove
2. Clean exterior of calipers.
3. Remove pad retaining pins and anti-rattle
springs.
4. Remove brake pads.
5. Clean exposed parts of pistons, using new brake
fluid. Wipe away excess with a lint free cloth.
6. Using piston clamp LRT-70-500press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.
Refit
7. Insert brake pads.
8. Position pad retaining springs, fit new pins and
spread ends.
9. Apply brake pedal several times to locate pads.
10. Fit road wheels. 130 Nm, 95 lbf ft.
11. Check fluid reservoir, top up if necessary, using
correct grade of fluid See LUBRICANTS,
BRAKES
9
REPAIR
FRONT BRAKE CALIPER ASSEMBLY
Key to caliper
1. Caliper
2. Bleedscrew
3. Anti-rattle springs
4. Pad retaining pins
5. Split [cotter] pin
6. Friction pads
7. Piston
8. Wiper seal retainer
9. Wiper seal
10. Fluid seal
11. Brake disc
70
BRAKES
10
REPAIR
FRONT BRAKE CALIPERS
Remove
1. Remove front road wheels.
2. Expose flexible brake hose by moving coiled
protective covering.
3. Using a hose clamp, clamp hose to prevent loss
of brake fluid.
4. Disconnect rigid brake pipe from flexible hose,
seal exposed ends to prevent ingress of dirt.
5. Remove split [cotter] pin, retaining pins and
springs, withdraw pads. If refitting pads, identify
them for assembly to original locations.
6. Remove 2 bolts and withdraw caliper from swivel
housing.
Refit
WARNING: Do not separate caliper halves
7. Clean outer surfaces of caliper using aerosol
brake cleaner.
8. Using special tool LRT-70-500, clamp pistons in
inboard half of caliper. Gently, keeping fingers
clear, and with CAUTION, apply air pressure to
fluid inlet port to expel pistons. It is unlikely that
pistons will expel at same time. Regulate rate
with a suitable piece of wood between
appropriate piston and caliper.
9. Finally remove pistons, identifying them with
their respective bores.
10. Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal. Pry
retainer carefully from mouth of bore.
11. Taking care not to damage seal grooves, extract
wiper seal and fluid seal.
12. Clean bores, pistons and seal grooves using
clean brake fluid only. If caliper or pistons are
corroded, or their condition is not perfect, new
parts must be fitted.
BRAKES
11
REPAIR
Assemble outboard pistons
13. Coat new fluid seal with brake fluid. Ease seal
into groove in bore using only fingers, ensuring it
is properly seated. Fluid seal and groove are not
same in section, so when seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14. Coat appropriate piston with brake fluid. Insert it
squarely into bore by hand only. Do not tilt piston
during insertion, leave approximately 8mm
projecting from bore.
15. Coat new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston and into bore recess. Use
piston clamp to press home seal retainer and
piston.
Mounting inboard pistons
16. Clamp outboard pistons and carry out same
procedure for removing and fitting outboard
pistons and seals, instructions 8 to 15.
Fit calipers and pads
17. Fit caliper, tighten bolts evenly to 82 Nm, 60
lbf/ft.
18. Connect brake flexible hoses to caliper. Tighten
19. Remove hose clamps.
20. Insert pads. Fit pins and springs, secure using
new split [cotter] pin.
21. Bleed brake system. See Brake System Bleed
22. Press brake pedal firmly several times to locate
friction pads.
23. Fit road wheels, remove axle stands. Finally
tighten road wheel nuts to 130 Nm, 96 lbf/ft.
24. Road test vehicle. Note that new friction pads
require bedding-in, this may take several
hundred miles before brakes are at maximum
efficiency.
FRONT BRAKE DISCS
Remove
1. Remove hub assembly. See FRONT AXLE
AND FINAL DRIVE, Repair, Front hub
assembly
2. Remove 5 hub to disc bolts.
3. Tap disc to separate from hub.
Refit
4. Locate disc to hub.
5. Apply Loctite 270 to disc bolts and tighten to 73
Nm, 54 lbf/ft.
6. Check total disc runout with a dial indicator, this
must not exceed 0,15 mm, 0.006 in. If necessary
reposition disc.
7. Fit hub assembly See FRONT AXLE AND
FINAL DRIVE, Repair, Front hub assembly
Disc reclamation
8. Check disc thickness. This dimension may be
machined to minimum thickness of 22 mm,
0.875 in - ventilated discs. Machine equal
amount off each face.
NOTE: The disc MUST BE renewed if the
minimum running thickness stamped on
the disc is recorded.
70
BRAKES
12
REPAIR
REAR BRAKE CALIPER ASSEMBLY
Key to rear caliper
1. Caliper
2. Bleed screw
3. Pad retaining springs
4. Brake pads
5. Piston
6. Wiper seal retainer
7. Wiper seal
8. Fluid seal
9. Retaining pins
BRAKES
13
REPAIR
REAR BRAKE CALIPERS
Before starting repair refer to General brake service
Remove
2. Using a recognised hose clamp, clamp flexible
brake hose above rear axle.
3. Remove brake pipe from rear brake caliper.
4. Seal pipe ends to prevent ingress of dirt.
5. Remove retaining pins and withdraw pads. If
same pads are to be refitted, identify them for
assembly in original positions.
6. Remove 2 bolts and withdraw caliper from rear
axle.
Refit
WARNING: Do not separate caliper halves.
7. Clean outer surfaces of caliper with aerosol
brake cleaner.
8. WITH CAUTION expel pistons from their bores
by applying air pressure to fluid inlet port. It is
unlikely both pistons will expel at same time,
regulate rate with a suitable piece of wood
inserted between two pistons.
9. Finally, remove pistons keeping them identified
with their respective bores.
10. Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal and pry
retainer carefully from mouth of bore.
11. Taking care not to damage seal grooves, extract
wiper seal and fluid seal.
12. Clean bores, pistons and particularly seal
grooves using clean brake fluid only. If caliper or
pistons are corroded or their condition is not
perfect new parts must be fitted.
13. Apply brake fluid to new seal. Fit seal into
groove in bore. When seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
70
BRAKES
14
REPAIR
14. Coat piston with brake fluid. Insert it squarely
into bore. Do not tilt piston during insertion and
leave 8mm, 0.2 in projecting from bore.
15. Coat a new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston into bore recess.
16. Using special tool LRT-70-500- piston clamp,
press home seal retainer and piston.
Mounting inboard piston
17. Carry out same procedure as for removing and
fitting outboard piston and seals, instructions 8 to
16.
Fit calipers and pads to vehicle
18. Fit caliper to axle, tighten bolts evenly to 82 Nm,
60 lbf ft.
19. Connect brake pipe to caliper. Tighten to 15 Nm,
11 lbf ft.
20. Remove clamp from flexible brake hose.
21. Insert pads and retaining springs, secure in
position with new retaining pins and spread
ends. Ensure retaining springs are located
correctly.
22. Bleed brake system. See Brake System Bleed
23. Press brake pedal firmly several times to locate
pads.
24. Fit road wheels, remove axle stands and finally
tighten road wheel nuts, 130 Nm, 95 lbf ft.
CAUTION: New brake pads require
bedding-in, for several hundred miles
before brakes are at maximum efficiency.
REAR BRAKE DISC
Remove
1. Remove rear hub assembly. See REAR AXLE
AND FINAL DRIVE, Repair, Rear hub
assembly .
2. Remove 5 nyloc nuts securing road speed
sensor ring to disc.
3. Remove sensor ring.
4. Remove disc bolts.
5. Remove disc from rear hub.
Refit
6. Fit disc to rear hub.
7. Apply loctite 270 and fit disc bolts. Tighten to 73
Nm, 54 lbf ft .
8. Using new nyloc nuts fit sensor ring.
9. Check total disc run out, this must not exceed
0,15 mm, 0.006 in. If necessary reposition disc.
10. Fit rear hub assembly. See REAR AXLE AND
FINAL DRIVE, Repair, Rear Hub Assembly .
Disc reclamation
11. Check disc thickness. The disc may be
machined to minimum thickness of 12 mm,
0.472 in. Machine equal amounts off each face.
NOTE: The brake disc MUST BE renewed if
the minimum running thickness stamped
on the disc is recorded.
BRAKES
15
REPAIR
TRANSMISSION BRAKE
1. Pin
2. Washer
3. C clip
4. Brake shoe
5. Cable lever
6. Hold down spring
7. Dished washer
8. Brake drum
9. Screw
10. Brake cable
11. Adjuster slide
12. Adjuster nut
13. Spring
14. Adjuster slide
15. Adjuster bolt
16. Dished washer
17. Hold down spring
18. Brake shoe
19. Hold down pin
20. Hold down pin
21. Abutment plate
22. Back plate
23. Spring
70
BRAKES
16
REPAIR
TRANSMISSION BRAKE SHOES
Remove
1. Park vehicle on level ground, chock road wheels
and release park brake. Alternatively, raise
vehicle on a ramp.
2. Disconnect rear propeller shaft from
transmission output flange at brake drum.
3. Slacken off transmission brake drum adjustment
bolt.
4. Remove single screw securing brake drum to
output flange.
5. Withdraw drum to expose brake assembly.
6. Release top and bottom springs from brake
shoes.
7. Grip dished washer with a pair of pliers, depress
washer and turn through 90 .
8. Remove dished washer, complete with hold
down spring and pin from both shoes.
9. Move brake shoes out from adjuster slides,
release from abutment plate and remove from
backplate.
10. Check that springs are satisfactory for continued
use.
NOTE: If new brake shoes are to be fitted,
the springs should also be renewed.
Refit
11. Locate RH brake shoe in slide and secure brake
shoe and lever assembly to backplate with hold
down pin, spring and dished washer.
12. Locate LH brake shoe in slide and fit abutment
plate between both brake shoes. Secure LH
shoe with hold down pin, spring and dished
washer.
13. Fit pull-off springs to brake shoes.
14. Fit brake drum. Tighten screw to 25 Nm, 18 lbf
ft.
15. Check that park brake lever is released.
16. Screw in and tighten adjuster bolt until brake
drum will not rotate by hand.
17. Tighten adjuster bolt to 25 Nm, 18 lbf ft to
ensure brake drum is locked.
18. Slacken off adjuster bolt by 1 turns to give
shoes a running clearance. Check that the drum
is free to rotate.
19. Fit propeller shaft to output flange. Tighten
20. Remove wheel chocks and check operation of
park brake.
BRAKES
17
REPAIR
PARK BRAKE CABLE
Remove
1. Park vehicle on level ground, chock road wheels
and release handbrake. Alternatively, raise
vehicle on ramp [hoist].
2. From inside vehicle, pull up handbrake gaiter.
3. Remove split [cotter] pin, clevis pin, washer and
disconnect cable from park brake lever.
4. Slacken off transmission brake drum adjusting
screw.
5. Disconnect propeller shaft from output flange.
6. Remove retaining screw and withdraw brake
drum.
7. Release park brake cable clevis from abutment
on cable lever, see J6337, and pull through
aperture in back plate.
8. Pull cable from heelboard and remove from
vehicle.
Refit
9. Feed new cable through heelboard ensuring
rubber grommet is correctly located.
10. Position cable over guide plate, insert through
backplate and connect to cable lever.
11. Fit cable to park brake lever and secure with
clevis pin and split [cotter] pin.
12. Fit brake drum. Tighten screw to 25 Nm, 18 lbf
ft.
13. Screw in and tighten adjuster bolt until brake
drum will not rotate by hand.
14. Tighten adjuster bolt further to 25 Nm, 18 lbf ft
to ensure brake drum is locked.
15. Slacken off adjuster bolt by 1 turns to give
brake shoes running clearance. Check that the
drum is free to rotate.
16. Slacken locknut and adjust cable to give the
park brake pawl 2 notches free movement on the
rachet before being fully operational on 3rd
notch (brake shoes are fully expanded against
drum).
NOTE: Cable adjustment is for a new cable
or to compensate for cable stretch. Cable
adjustment must not be used to take up
brake shoe wear.
17. Fit propeller shaft to output flange. Tighten
18. Remove wheel chocks and check operation of
handbrake.
BRAKES
1
OVERHAUL
Key to master cylinder
1. Water ingress seal
2. Transfer housing
3. Vacuum seal
4. Guide ring
5. Retaining ring
6. O ring seal
7. Primary plunger assembly
8. L seal
9. Secondary plunger
10. Washer
11. Recuperating seal - primary cup
12. Seal retainer
13. Springs - 2 off
14. Swirl tube
15. Master cylinder body
16. Reservoir seals
17. Reservoir
18. Low fluid level switch and cap
70
BRAKES
2
OVERHAUL
MASTER CYLINDER
Before starting overhaul procedure refer to general
brake service practice. See Repair, General brake
service practice
Dismantling master cylinder
1. Disconnect battery and remove master cylinder
from servo See Repair, Master cylinder
2. Before commencing overhaul procedure
thoroughly clean master cylinder and inspect
outer surfaces for damage and condition, renew
complete assembly if necessary.
3. The reservoir is a push fit in master cylinder and
secured by seals. Carefully ease reservoir from
master cylinder by rolling it from seals as
illustrated.
4. Using soft jaws, one either side of master
cylinder flange and clamp flange in a suitable
vice. Remove water ingress O ring seal from
master cylinder to servo flange and discard.
5. Hold outside of transfer housing with a suitable
pair of grips, carefully pull, while working pliers in
a backwards and forwards rocking motion to
ease housing off master cylinder, discard
housing and vacuum seal.
6. Withdraw 2 reservoir seals from master cylinder
inlet ports, seals are different and should be
noted for assembly. Discard both seals.
7. Remove retaining ring and O ring seal from
machined outer surface of master cylinder,
discard both seal and retaining ring.
BRAKES
3
OVERHAUL
8. Remove guide ring from mouth of master
cylinder which supports primary plunger
assembly and place to one side, this component
is not part of master cylinder service kit and is to
be refitted on assembly of unit.
9. Pull primary plunger assembly out of master
cylinder.
NOTE: The primary plunger assembly
cannot be broken down any further and is
serviced as a complete unit. Discard
assembly.
10. The secondary plunger assembly will remain at
bottom of master cylinder bore, plunger can be
easily expelled by tapping assembly on a piece
of timber until plunger appears at cylinder mouth,
carefully pull plunger out of master cylinder.
11. If swirl tube was not expelled at same time as
secondary plunger, repeat above operation to
expel it from bottom of master cylinder bore and
discard.
12. Clean all parts with Girling cleaning fluid or
unused brake fluid and place cleaned parts on to
a clean sheet of paper. Inspect cylinder bore and
plungers for signs of corrosion, ridges and score
marks. Provided working surfaces are in perfect
condition, new seals from a Girling Service
repair kit may be used.
Renewing secondary plunger seals
13. Remove following components from secondary
plunger and discard:
NOTE: A small screwdriver with end
rounded and polished is required to
remove L seal. DO NOT damage
secondary plunger. A. Springs B. Seal retainer C.
Recuperating seal (primary cup) D. Washer E. L
seal
14. Coat new seals in unused brake fluid and firstly
fit L seal to plunger.
15. Fit washer followed by recuperating seal. Fit seal
retainer and springs, ensure springs are
correctly seated.
70
BRAKES
4
OVERHAUL
Assembling master cylinder
CAUTION: It is important that the following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly.
NOTE: Thoroughly check that no debris is
lodged in fluid passageways and drillings.
If debris is found, carefully remove,
re-clean cylinder and re-check.
16. Fit new swirl tube to bottom of cylinder bore.
17. Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
18. Fit primary plunger assembly using same
method as for secondary plunger, push plunger
down bore.
19. Fit original guide ring to support primary plunger.
20. Coat a new O ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: O ring should not be rolled
down outer location surface of master
cylinder but should be slightly stretched
and eased down cylinder and into its groove. Do
not over stretch seal.
21. Fit a new retaining ring on outer surface of
master cylinder ensuring that serrations of ring
are facing mounting flange.
22. Fit two new reservoir seals in ir respective ports.
23. Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger guide ring.
24. Lubricate vacuum seal with brake fluid, fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange. Do
not adjust transfer housing after fitting.
25. Lubricate a new water ingress seal with brake
fluid, slightly stretch seal and ease it down
housing until seal is in correct position between
housing and flange.
26. Roll reservoir into top of master cylinder,
reversing procedure described in instruction 3.
27. Fit master cylinder to servo. See Repair,
Master cylinder
28. Reconnect battery, and road test vehicle.
BRAKES
1
TORQUE VALUES
Brakes Nm lbf ft
Brake pipe connections to:
- Pressure reducing valve 15 ....................................... 11
- Brake calipers 15 ....................................................... 11
- Master cylinder 15 ...................................................... 11
Flexible hoses to calipers 15 ................................................. 11
Bleed screws 15 .................................................................... 11
Brake caliper to swivel pin housing 82 .................................. 60
Brake disc bolts* 73 .............................................................. 54
Brake drum screw 25 ............................................................ 18
Rear propeller shaft flange 46 ............................................... 34
Brake drum adjuster bolt 25 .................................................. 18
Servo assembly to pedal box 26 ........................................... 19
Pedal box to engine bulkhead 25 .......................................... 18
Master cylinder to servo 26 ................................................... 19
Road wheels 130 .................................................................... 95
* Apply Loctite 270 before assembly
WHEELS AND TYRES
1
TYPES OF WHEEL RIMS AND TYRES
Description
The vehicle is equipped with alloy wheels and
tubeless radial ply tyres.
Tyre codes
The writing, codes and numbers moulded into the tyre
wall vary between tyre manufacturers, however most
tyres are marked with the information shown in the
illustrated example.
NOTE: The illustration is an example of the
type of markings moulded into tyres and is
for guidance only. For specific tyre
specifications See GENERAL SPECIFICATION
DATA, Information, Tyre size and pressures .
1. Type of tyre construction - Radial Ply
2. Load index - 104
3. Speed symbol - S or T
4. USA Tyre quality grading - Tread wear 160
Traction A temperature B
5. Tread wear indicators moulded into tread pattern
are located at intervals around the tyre and
marked by a code - E66 103S6
6. Tyres with Mud Snow type tread pattern are
marked - M&S
7. Tyre reinforcing mark - Reinforced
8. USA Load and pressure secification -
1260Kg(2778LBS) at 450kPa (65psi)
9. Tyre size - 265/75 R16 All Terrain
10. Type of tyre - TUBELESS
11. Country of manufacture - MADE IN GREAT
BRITAIN
12. USA Compliance symbol and identification -
DOT AB7C DOFF 267
13. European type approval identification - E11
01234
14. Tyre construction - SIDE WALL 2 PLIES
RAYON. TREAD 2 RAYON 2 STEEL
15. Manufacturers brand name/type - TRACTION
PLUS mzx M
WHEELS AND TYRES
1
FAULT DIAGNOSIS
TYRE WEAR CHART
FAULT CAUSE REMEDY
Rapid wear at Tyres under-inflated Inflate to correct pressure
shoulders Worn suspension components Replace worn components
i.e. ball joints, panhard
rod bushes,steering damper
Excessive cornering speeds
Rapid wear at
centre
Tyres over-inflated Inflate to correct pressure
of tread
Wear at one
shoulder
Track out of adjustment Adjust track to correct figure
Bent panhard rod Check and replace worn or damaged
components
Bald spots or tyre Wheel out of balance Balance wheel and tyre
cupping assembly
Excessive radial runout Check runout and replace tyre
if necessary
Shock absorber worn Replace shock absorber
Excessive braking
Tyre scalloped Track out of adjustment Adjust toe to correct figure
Worn suspension components Replace as necessary
Excessive cornering speeds
CAUTION: This diagnosis chart is for general guidance only and does not necessarily include
every cause of abnormal tyre wear.
74
WHEELS AND TYRES
2
FAULT DIAGNOSIS
FAULT - SYMPTOMS
Vibration through steering wheel
1. Check tyre pressures. See Repair, Tyre
Pressures
2. Check condition of tyres. See Tyre Wear Chart
3. Check front wheel alignment See STEERING,
Adjustment, Front Wheel Alignment
4. Check wheel balance. See Repair, Wheel
Balancing
NOTE: In the event that any apparent
vibration is not eliminated at this stage.
See PROPELLER SHAFTS, Fault
diagnosis, Vibration Harshness
NOTE: Radial ply tyres have a flexible
sidewall, which produces a sidewall bulge
making the tyre appear under-inflated.
This is a normal condition for radial ply tyres. Do
not attempt to reduce this bulge by over-inflating
the tyre.
1. Correct inflation.
2. Under-inflation.
3. Over-inflation.
4. Tread contact with road.
WHEELS AND TYRES
1
REPAIR
GENERAL INFORMATION
WARNING: This is a multipurpose vehicle
with wheels and tyres designed for both
on and off road usage. Only use wheels
and tyres specified for use on the vehicle.
The vehicle is equipped with tubeless radial ply tyres
as standard equipment. The tyres are of European
metric size and must not be confused with the P size
metric tyres available in North America.
Vehicle wheel sets, including spare wheel, must be
fitted with the same make and type of tyre to the
correct specification and tread pattern. Under no
circumstances must cross-ply or bias-belted tyres be
used.
For tyre specification and pressures. See GENERAL
SPECIFICATION DATA, Information, Wheels and
Tyres
Alloy Wheels
Tubeless tyres are mounted on 7.0 inch wide by 16
inch diameter cast aluminium alloy wheels. The
surface has a paint finish covered with a clear
polyurethane lacquer. Care must be taken when
handling the wheel to avoid scratching or chipping the
finish.
The alloy wheel rim is of the asymmetric hump
type incorporating a safety hump to improve
location of the tyre bead in its seat. If difficulty is
experienced in fitting tyres to this type of rim. See
Tyre Fitting
WARNING: DO NOT fit an inner tube to an
alloy wheel.
TYRE INSPECTION
Inspect tyres at weekly intervals to obtain maximum
tyre life and performance and to ensure compliance
with legal requirements. Check for signs of incorrect
inflation and uneven wear, which may indicate a need
for balancing or front wheel alignment, if the tyres
have abnormal or uneven wear patterns. See Fault
diagnosis, Tyre Wear Chart
Check tyres at least weekly for cuts, abrasions, bulges
and for objects embedded in the tread. More frequent
inspections are recommended when the vehicle is
regularly used in off road conditions.
To assist tyre inspection, tread wear indicators are
moulded into the bottom of the tread grooves, as
shown in the illustration below.
When the tread has worn to a remaining depth of 1.6
mm, 0.06 in the indicators appear at the surface as
bars which connect the tread pattern across the width
of the tread as shown in the illustration below.
74
WHEELS AND TYRES
2
REPAIR
When the indicators appear in 2 or more adjacent
grooves, at 3 locations around the tyre, a new tyre
must be fitted.
NOTE: DO NOT attempt to interchange
tyres, e.g. from front to rear, as tyre wear
produces characteristic patterns
depending on their position. If tyre position is
changed after wear has occured, the performance
of the tyre will be adversely affected.
NOTE: Territorial vehicle regulations
governing tyre wear MUST be adhered to.
WHEELS INSPECTION
Regularly check the condition of the wheels. Replace
any wheel that is bent, cracked, dented or has
excessive runout.
VALVES INSPECTION
Check condition of inflation valve. Replace any valve
that is worn, cracked, loose, or leaking air.
TYRE PRESSURES
Maximum tyre life and performance will be
obtained only if tyres are maintained at the correct
pressures .
Tyre pressures must be checked at least once a week
and preferably daily, if the vehicle is used off road.
The tyre inflation pressure is calculated to give the
vehicle satisfactory ride and steering characteristics
without compromising tyre tread life. For
recommended tyre pressures in all conditions See
GENERAL SPECIFICATION DATA, Information,
Wheels and Tyres
Always check tyre inflation pressures using an
accurate gauge and inflate tyres to the
recommended pressures only .
Check and adjust tyre pressures ONLY when the
tyres are cold, vehicle parked for three hours or more,
or driven for less than 3 km, 2 miles at speeds below
65 km/h, 40 mph. Do not reduce inflation pressures if
the tyres are hot or the vehicle has been driven for
more than 3 km, 2 miles at speeds over 65 km/h, 40
mph, as pressures can increase by 0.4 bar, 6 lb/in
2
over cold inflation pressures.
Check ALL tyre pressures including the spare. Refit
the valve caps as they form a positive seal and keep
dust out of the valve.
WHEELS AND TYRES
3
REPAIR
WHEEL BALANCING
CAUTION: It is essential that all wheel
balancing is carried out off the vehicle.
The use of on the vehicle balancing could
cause component damage or personal injury and
MUST NOT be attempted.
NOTE: Before attempting to balance a
wheel and tyre assembly clean all mud and
dirt deposits from both inside and outside
rims and remove existing balance weights.
Remove stones from the tyre tread in order to avoid
operator injury during dynamic balancing and to obtain
the correct balance.
Inspect tyres for damage and correct tyre pressures
and balance according to the equipment
manufacturers instructions.
Alloy wheels
Clean area of wheel rim and attach adhesive balance
weights in position shown. Cut through rear face of
weight strip to detach required weights.
CAUTION: Use only correct adhesive
balance weights to avoid damage to
aluminium wheel rim. DO NOT attempt to
use a steel wheel weight on an aluminium wheel.
74
WHEELS AND TYRES
4
REPAIR
Static balance
Wheel tramp
A. Heavy spot.
B. Add balance weights here.
C. Centre line of spindle.
Static balance is the equal distribution of weight
around the wheel. A statically unbalanced wheel will
cause a bouncing action called wheel tramp. This
condition will eventually cause uneven tyre wear.
Dynamic balance
Wheel shimmy
A. Heavy spot.
B. Add balance weights here.
C. Centre line of spindle.
Dynamic balance is the equal distribution of weight on
each side of the centre line so that when the wheel
spins there is no tendency for side to side movement.
A dynamically unbalanced wheel will cause wheel
shimmy.
WHEELS AND TYRES
5
REPAIR
Off vehicle balancing
Balance wheel assembly referring to equipment
It is essential that the wheel is located by the centre
hole NOT the stud holes. To ensure positive wheel
location the diameter of the locating collar on the
machine shaft must be 112.80 to 112.85 mm, 4.441 to
4.443 in. This diameter will ensure that the collar fits
correctly within the centre hole of the wheel.
Where possible always use the vehicle wheel
retaining nuts to locate the wheel on the balancer, to
avoid damaging the wheel. If this is not possible, the
locating nuts must be of a similar pattern to the
original wheel nuts. The use of conical type wheel
nuts for this purpose may damage the surface on alloy
wheels.
Cleaning
Wash the aluminium wheels using a suitable wash
and wax concentrate correctly diluted and rinse with
cold clear water. DO NOT use abrasives or aluminium
wheel cleaners containing acid, as they will destroy
the lacquer finish.
Tyre changing
Use only tyre changing equipment to mount or
demount tyres, following the equipment
manufacturers instructions. DO NOT use hand tools
or tyre levers, as they may damage tyre beads or the
wheel rim.
Puncture repair
Remove punctured tyre from wheel and repair using a
combination service plug and vulcanising patch.
Always follow manufacturers instructions when using
a puncture repair kit.
Only punctures in tread area are repairable, DO NOT
attempt to repair punctures in tyre shoulders or
sidewalls.
Do not attempt to repair a tyre that has sustained the
following: bulges or blisters, ply separation, broken or
cracked beads, wear indicators visible and punctures
larger than 6 mm diameter.
CAUTION: Do not use tyre sealants that
are injected through valve stem to repair
punctured tyres, they may produce wheel
corrosion and tyre imbalance.
Aluminium wheel rim bead seats should be cleaned
using a non-abrasive cleaner to remove the mounting
lubricants and old rubber. Before mounting or
demounting a tyre, bead area should be well
lubricated with a suitable tyre lubricant.
TYRE FITTING
Alloy wheels
1. Install a new valve assembly.
2. Ensure wheel and tyre is adequately lubricated.
3. Mount tyre in normal manner. Inflate tyre and at
same time apply hand pressure to area around
valve to aid seating over valve first.
NOTE: Stop inflation immediately if tyre
seats opposite valve, as this will result in
valve being blocked by tyre beading,
making further inflation impossible, and carry out
following procedure.
4. Deflate tyre, unseat and rotate it around the rim
until valve is in line with that part of tyre which
seated initially. This part of beading having
seated over hump previously will automatically
seat first when tyre is re-inflated.
5. Inflate tyre to seat beads correctly, finally inflate
to correct pressure.
74
WHEELS AND TYRES
6
REPAIR
WHEELS
Remove
WARNING: The parking brake acts on the
transmission, not rear wheels, and may
not hold vehicle when jacking unless the
following procedure is used. If one front wheel
and one rear wheel is raised, no vehicle holding or
braking effect is possible. Wheels MUST be
chocked in all circumstances.
Apply parking brake, select P in main gearbox
and engage low gear in transfer box.
1. Loosen 5 wheel nuts.
2. Using a suitable trolley jack, raise vehicle and
place on axle stands. See INTRODUCTION,
Information, Jacking
3. Remove wheel nuts and carefully withdraw
wheel over studs.
Refit
4. Ensure that retaining studs and nuts are clean.
5. Alloy wheels: Lightly coat wheel mounting spigot
face with a suitable anti-seize compound to
minimise possibility of adhesion between wheel
and spigot face.
6. Refit wheel taking care not to damage stud
threads. (Do not apply oil).
7. Fit wheel nuts and turn by hand for at least 3 full
threads before using any form of wheel wrench.
8. Tighten nuts as much as possible using a
suitable wrench.
9. Lower vehicle and finally tighten nuts to correct
torque in sequence shown. 130 Nm, 95 lbf ft .
WHEEL STUD
Remove
1. Remove wheel. See Wheels
2. Drive stud out of driveshaft flange.
Refit
3. Position stud in flange.
4. Install a suitable spacer over stud.
5. Using a M16 x 1.5 nut, a slave wheel nut is
suitable, pull stud into flange until shoulder of
stud abuts flange.
6. Refit wheel. See Wheels
CHASSIS AND BODY
1
CHASSIS AND BODY
Chassis
The chassis on all Defender variants are of the box
section, ladder type construction, manufactured from
2 mm (14swg) steel and treated with zinc phosphate,
cathodic electro coated, followed by waxing in the rear
crossmember.
Outriggers and angled brackets welded to the chassis
support suspension and axle components and are
also used as body mounting points. A detachable box
section crossmember, located between the two
chassis longitudinals, is fitted to facilitate main
gearbox and tranfer box assembly removal.
Should chassis damage occur a comprehensive range
of components are available, including body support
outriggers, cross members and radius arm mounting
brackets. ALWAYS fit genuine parts that are fully
guaranteed and to original equipment specification,
fitted with Land Rovers BS 5135 welding standard.
Body
All body panels, with the exception of the fascia
bulkhead, are manufactured from aluminium alloy.
Galvanized steel is used for the front wheel arches to
give optimum protection. Most panels are also treated
with zinc phosphate and cathodic electrocoated with
polyester surfacer, and are bolted to the welded
chassis.
76
CHASSIS AND BODY
2
CHASSIS AND BODY
3
CHASSIS ALIGNMENT DIMENSIONS
A Front Datum
B Chassis Datum
C Front axle centre line
D Rear axle centre line
1. 239,0 - 236,5 mm 9.41 - 9.31 in
2. 82,0 - 79,5 mm 3.23 - 3.13 in
3. 633 mm 24.921 in
4. 2420,6 - 2418,6 mm 94.51 - 95.22 in
5. 2306,4 - 2305,4 mm 90.80 - 90.76 in
6. 981,2 - 978,7 mm 38.63 - 38.53 in
7. 182,7 mm 7.19 in
8. 41,5 - 37,0 mm 1.63 - 1.46 in
9. 252 - 250 mm 9.92 - 9.84 in
10. 110 mm 4.33 in
11. 2360mm - 92.91 in - Wheelbase
12. 636 - 634 mm 25.04 - 24.96 in
13. 488 - 483 mm 19.21 - 19.01
14. 488 - 483 mm 19.21 - 19.01 in
15. 3431,1 - 3426,1 mm 135.08 - 134.89 in
16. 588,3 - 586,3 mm 23.16 - 23.08 in
17. 2313,8 - 2311,8 mm 91.09 - 91.06 in
18. 590,5 mm 23.25 in
19. 295,25 mm 11.62 in
20. 519,60 - 517,00 mm 20.46 - 20.35 in
21. 259,80 - 258,50 mm 10.23 - 10.18 in
22. 1242,6 - 1240,6 mm 48.92 - 48.84 in
23. 642,5 - 639,5 mm 25.30 - 25.18 in
24. 750,9 mm 29.56 in
25. 439,5 - 436,5 mm 17.30 - 17.18 in
26. 136,5 mm 5.37 in
27. 299,5 - 295,5 mm 11.79 - 1163 in
28. 103 - 100 mm 4.06 - 3.94 in
29. 131,5 - 126,5 mm 5.18 - 4.98 in
30. 705,5 - 704,5 mm 27.76 - 27.74 in
31. 705,5 - 704,5 mm 27.76 - 27.74 in
32. 42,2 - 40,2 mm 1.66 - 1.58 in
33. 491 - 486 mm 19.33 - 19.13 in
34. 594,2 - 593,4 mm 23.39 - 23.36 in
35. 283,0 - 282,2 mm 11.14 - 11.11 in
36. 32,25 - 31,25 mm 1.27 - 1.23 in
37. 397 - 395 mm 15.63 - 15.55 in
76
CHASSIS AND BODY
4
Chassis frame alignment
With the vehicle assembled a check for chassis
squareness can be made as follows:
1. Place the vehicle on a level floor.
2. Mark measuring points at approximately the
locations shown, ensure that the marks are
exactly opposite on each side of the chassis
frame.
3. Hold a plumb line against each of the measuring
points in turn and mark the floor directly beneath
the plumb-bob.
4. Move the vehicle and measure diagonally
between the marks made on the floor, if the
chassis is square the diagonals between the
related measuring points should agree within
9,50 mm.
5. Chassis frame dimensional checks can be
made, with the vehicle upper structure removed,
referring to the applicable illustration and
associated key.
CHASSIS AND BODY
1
ADJUSTMENT
DOOR LOCK STRIKER - ADJUST
Adjust
1. Loosen Torx bolts securing striker to B post.
2. Adjust alignment of striker vertically and
horizontally, lightly tighten bolts.
3. Close door, check for correct latching with door
lock and for centring on striker.
4. Add or remove packing shims as necessary.
Fully tighten bolts.
5. Carry out further adjustment as necessary. If full
adjustment cannot be achieved carry out
following:
6. Remove striker and nut plate.
7. Elongate striker bolt holes in B post to increase
movement in direction required.
8. Refit striker and adjust as necessary.
TAIL DOOR STRIKER - ADJUST
Adjust
1. Loosen striker securing screws.
2. Adjust striker vertically and horizontally, lightly
tighten screws.
3. Close door and check for correct latching with
door lock.
4. Carry out further adjustment as necessary. If full
adjustment cannot be achieved carry out
following:
5. Remove striker and nut plate.
6. Elongate holes in body panel in direction
required.
7. Refit striker and adjust as necessary.
CHASSIS AND BODY
1
REPAIR
FRONT DOOR - HARD TOP
Front door lock mechanism - RH shown
76
CHASSIS AND BODY
2
REPAIR
TRIM CASING - FRONT DOOR
Remove
1. Prise open finisher caps, remove 2 screws, and
detach door pull.
2. Remove single screw behind remote control
lever.
3. Prise off remote control lever bezel.
4. Prise off door locking button bezel.
5. Prise out window regulator handle centre
finisher, remove retaining screw, and withdraw
handle and bezel.
6. Using a screwdriver to release trim fasteners,
carefully ease trim casing from door.
CHASSIS AND BODY
3
REPAIR
Refit
7. Remove any trim fasteners held in door panel.
Refit or insert new clips to trim casing.
8. Ensure that anti-vibration pads are in position
and offer-up trim casing to door. Line-up
fasteners with holes in door and firmly push trim
into position.
9. Fit bezels to locking button and remote control
lever.
10. Fit single screw behind remote control lever.
11. Fit door pull and secure with 2 screws and
finisher caps.
12. Fit window regulator handle and retain with
single screw and finisher.
MOUNTING PANEL - FRONT DOOR
Remove
1. Remove door trim casing See Trim casing -
front door and plastic sheet.
2. Remove 4 screws securing window regulator to
mounting panel.
3. Remove 5 screws securing mounting panel to
door frame.
76
CHASSIS AND BODY
4
REPAIR
4. Release remote control lever rod from latch
mechanism and from plastic clip in mounting
panel.
5. Slide window regulator arm from mounting panel
channel and remove panel with remote control
lever and rod.
Refit
6. Engage window regulator arm in mounting panel
channel.
7. Connect remote control rod to latch mechanism
8. Fit mounting panel and retain with 5 screws.
9. Secure window regulator to mounting panel with
4 screws.
10. Raise and lower window to check for free
movement.
11. Fit plastic sheet and door trim casing. See Trim
casing - front door
SILL LOCKING BUTTON - FRONT DOOR
Remove
1. Remove door trim casing. See Trim casing -
front door
2. Peel back plastic sheet to expose mechanism.
3. Release spring clip and disconnect operating rod
from latch mechanism.
4. Remove 2 screws and withdraw locking button
assembly.
Refit
5. Secure locking button assembly to door with 2
screws.
6. Connect operating rod to latch mechanism and
secure with spring clip.
7. Re-seal plastic sheet and fit door trim casing.
See Trim casing - front door
CHASSIS AND BODY
5
REPAIR
WINDOW REGULATOR - FRONT DOOR
Remove
front door
2. Remove plastic sheet.
3. Temporarily fit handle, position window half open
and support with a length of timber.
4. Remove 2 lower screws securing mounting
panel to door and slacken 3 upper screws.
5. Remove 4 screws retaining window regulator to
mounting panel and slide operating arms from
channels attached to glass and mounting panel
and remove regulator.
Refit
6. Insert regulator operating arms into channels.
7. Fit and tighten mounting panel lower screws and
tighten upper screws.
8. Align holes in regulator with holes in mounting
panel and secure with 4 screws.
9. Temporarily fit regulator handle and check that
glass can be raised and lowered without tight
spots.
10. Secure plastic sheet.
11. Fit door trim casing. See Trim casing - front
door
REMOTE CONTROL LEVER - FRONT DOOR
Remove
1. Remove door trim. See Trim casing - front
door
2. Peel back sufficient of plastic sheet to gain
access to remote lever.
3. Release spring clip and disconnect control rod
from latch mechanism.
4. Release control rod from plastic clip in mounting
panel.
5. Remove 2 screws securing remote control lever
to mounting panel and withdraw lever and
control rod.
76
CHASSIS AND BODY
6
REPAIR
Refit
6. Feed control rod into position and loosely secure
lever to mounting panel with 2 screws.
7. Connect control rod to latch mechanism and
8. Tighten control lever retaining screws.
9. Secure control rod to plastic clip in mounting
panel.
10. Secure plastic sheet with adhesive.
door
EXTERIOR HANDLE - FRONT DOOR
Remove
front door
2. Remove mounting panel. See Mounting panel
- front door and support glass with timber.
3. Disconnect operating rod from handle
mechanism.
4. Disconnect rod from locking barrel lever.
5. Remove 2 screws and withdraw handle
assembly.
CHASSIS AND BODY
7
REPAIR
Refit
6. Fit handle to door ensuring that two bezels are in
position - flat faces towards door, and secure
with 2 screws.
7. Connect rod to handle operating lever and
8. Connect rod to locking barrel lever and retain
with spring clip.
9. Fit mounting panel See Mounting panel - front
door
door
76
CHASSIS AND BODY
8
REPAIR
LATCH ASSEMBLY - FRONT DOOR
Remove
- front door and support glass with timber.
2. Disconnect control rod from handle operating
lever.
3. Disconnect control rod from locking lever on
handle.
4. Disconnect locking button control rod from latch
mechanism.
5. Remove 2 screws and remove handle assembly
from door.
6. Remove 2 self-tapping screws retaining lower
end of window glass runner.
7. Remove 3 screws securing latch assembly to
door.
8. Whilst taking care not to damage runner, ease
runner away from latch and manoeuvre latch
asembly from door.
Refit
9. Carefully ease window runner away, sufficiently
to enable latch to be located into position.
10. Secure latch to door with 3 screws.
11. Secure window runner with 2 screws ensuring
that packing strip is in position and that screw
heads are below bottom of runner to prevent
damage to glass.
12. Fit handle with 2 screws, ensuring that bezels
are in position.
13. Connect control rod to handle operating lever
and secure with spring clip.
14. Connect control rod to locking lever and retain
with spring clip.
15. Connect locking button control rod to latch lever
and secure with spring clip.
16. Fit mounting panel. See Mounting panel -
front door
CHASSIS AND BODY
9
REPAIR
DOOR GLASS - FRONT DOOR
Remove
- front door
2. Remove window regulator. See Window
regulator - front door
3. Push glass up to top of its travel and support
with a suitable length of timber.
4. Remove 2 self tapping screws securing window
glass runner on latch side of door and single
screw from hinge side.
5. Taking care not to damage paint, prise exterior
waist weather strip from door.
6. Remove timber support and lower glass to
bottom of door.
7. Ease runner from glass at hinge side of door, lift
glass over bottom edge of door and withdraw.
76
CHASSIS AND BODY
10
REPAIR
Refit
8. Insert glass into runners at an angle as
illustrated.
9. Whilst lifting glass, position it squarely in
runners, raise to top of travel and insert timber
support.
10. Secure hinge side runner with single screw
ensuring that packing strip is in position.
11. Locate packing strip and secure opposite runner
with 2 screws. Ensure that all 3 screw heads are
well below bottom of runners to prevent damage
to glass.
12. Locate regulator in window lift channels.
13. Fit mounting panel See Mounting panel - front
door
LOCKING BARREL - FRONT DOOR
Remove
1. Remove door trim See Trim casing - front
door and plastic sheet.
2. Remove mounting panel See Mounting panel
- front door
3. Raise and support glass to gain access to latch
mechanism.
4. Release spring clip and disconnect rod from lock
operating lever.
5. Remove single screw and withdraw lock lever
assembly.
6. Withdraw lock barrel from exterior door handle
complete with locking sleeve.
CHASSIS AND BODY
11
REPAIR
7. To remove barrel from plastic retaining sleeve,
depess spring loaded button and withdraw
sleeve.
Refit
NOTE: If a new barrel is being fitted, check
that number on barrel coincides with
number on accompanying key.
8. Push plastic retaining sleeve over barrel until
spring loaded peg locks it into position.
9. Fit barrel and plastic sleeve assembly to locking
sleeve and insert into exterior handle reversing
instruction 6.
10. Assemble lock lever components as illustrated
and from inside of door panel, fit them to barrel
assembly with single screw.
11. Connect operating rod to lock lever and secure
with spring clip, reversing instruction 4.
12. Fit mounting panel. See Mounting panel -
front door
REAR SEAT CUSHION
Remove
1. Release seat cushion stowage strap.
2. Remove 4 bolts and spring washers and lift seat
cushion from pivot brackets.
3. Remove 4 bolts, plain washers, spring washers
and nuts. Detach both pivot brackets from wheel
arch.
Refit
4. Secure pivot brackets to wheel arch and tighten
5. Position seat cushion in pivot brackets and
secure with 4 bolts and spring washers.
6. Fit stowage strap.
76
CHASSIS AND BODY
12
REPAIR
REAR SEAT SQUAB
Remove
1. Release seat cushion stowage strap and lower
seat cushion.
2. Loosen 2 bolts securing seat squab brackets to
body side.
3. Remove 2 bolts, plain washers, spring washers
and nuts securing seat squab to wheel arch.
4. Lift and release brackets from retaining bolts and
remove seat squab.
Refit
5. Lower seat squab brackets over retaining bolts,
tighten bolts to 10 Nm, 7 lbf ft .
6. Secure seat squab to wheel arch, tighten bolts to
10 Nm, 7 lbf ft.
7. Raise seat cushion and fit stowage strap.
CHASSIS AND BODY
13
REPAIR
REAR SEAT BELTS
Remove
1. Release belt straps from buckles on both seats.
2. Raise both seat cushions and secure with
stowage straps.
3. Unscrew bolt and remove bracket and inner seat
belt straps.
4. Unscrew bolt and remove rear seat buckle strap
from wheel arch.
5. Unscrew bolt and remove front seat buckle strap
from interior roll-over bar mounting.
Refit
6. Reverse removal procedure, ensuring seat belt
fixing bolts are tightened to 32 Nm, 24 lbf ft).
76
CHASSIS AND BODY
14
REPAIR
FRONT SEAT BELTS
Remove
1. Remove cap and unscrew seat belt guide
bracket fixing bolt from B/C post.
2. Remove 3 bolts and plain washers securing seat
belt mounting bracket to body on outside of seat
base.
3. Prise seat belt retaining clip from side of seat
mounting and remove trim studs.
4. Unscrew bolt and remove seat belt inertia reel
from roll-over bar mounting bracket.
5. Remove seat belt and inertia reel assembly.
6. Unscrew bolt and washer and remove seat belt
buckle stalk from roll-over mounting bracket.
7. On the drivers side, disconnect harness plug
connector of audible warning circuit at buckle
stalk.
Refit
8. Reconnect harness plug of audible warning
circuit.
9. Position stalk on roll-over bar mounting bracket
and tighten fixing bolt to 32 Nm, 24 lbf ft.
10. Secure seat belt inertia reel to roll-over bar
mounting and tighten bolt to 32 Nm, 24 lbf ft.
11. Secure seat belt backet to floor on outside of
seat base and tighten bolts to 23 Nm, 17 lbf ft).
12. Fit seat belt retaining clip to side of seat base
and secure with trim studs.
13. Extend belt from inertia reel, secure slide bracket
to B/C post and tighten bolt to 32 Nm, 24 lbf ft.
14. Refit fixing bolt cap.
CHASSIS AND BODY
15
REPAIR
SIDE TRIM PANEL - HARD TOP
Remove
1. Remove rear seat squabs. See Rear seat
squab
2. Remove rear end trim panel. See Rear end
trim panel - hard top
3. Prise cap from front seat belt upper guide
retaining bolt.
4. Unscrew retaining bolt and remove seat belt
from B/C post.
5. Carefully prise 2 trim studs from B/Cpost.
6. Remove 4 bolts securing side trim panel and
forward seat support to body side.
7. Release top edge of side trim panel by striking
upwards with the hand to disengage 3 spring
clips.
8. Carefully pull trim panel rearwards to clear
interior roll-over bar.
9. Remove side trim panel from vehicle.
Refit
10. Fit new spring clips to the 3 brackets on top
edge of side trim panel.
11. Carefully pull trim panel behind interior roll-over
bar.
12. Align trim panel, ensuring it is correctly
positioned around side window.
13. Locate trim panel spring clips on inner cant rail
and press firmly down to secure top edge of trim
panel.
14. Align bosses of trim panel and forward seat
support bracket with body side fixing holes and
secure with bolts and washers. Do notfully
tighten at this stage.
15. Fit trim stud to secure bottom edge of trim panel
to B/C post.
16. Secure seat belt guide to B/C post, tighten bolt
to 32 Nm, 24 lbf/ft and fit cap.
17. Fit rear end trim panel. See Rear end trim
panel - hard top
18. Fit rear seat squab. See Rear seat squab
76
CHASSIS AND BODY
16
REPAIR
REAR END TRIM PANEL - HARD TOP
Remove
1. Pull edge of rear end trim panel firmly to release
the two spring retaining clips from vertical rail at
door aperture.
2. Remove rear end trim panel.
Refit
3. Fit new spring clips to the two brackets on side
of trim panel.
4. Position outboard edge of trim panel in corner to
abut side trim panel and locate spring clips on
vertical rail.
5. Press edge of trim panel firmly to secure in
position.
REAR GRAB HANDLE - HARD TOP
Remove
1. Carefully prise top and bottom edges of finisher
caps from grab handle and then hinge outwards
to gain access to fixing screws.
2. Remove 4 fixing screws and detach grab handle
from rear end trim panel.
Refit
3. Position grab handle on rear end trim panel and
secure with 4 fixing screws.
4. Press finisher caps over screws.
CHASSIS AND BODY
17
REPAIR
REAR END LINING - HARD TOP
Remove
2. Remove rear grab handles. See Rear grab
handle - hard top
3. Carefully prise out 6 trim studs securing rear end
lining to mounting brackets.
4. Remove rear end lining.
Refit
5. Position rear end lining on mounting brackets
and secure with 6 trim studs.
6. Fit rear grab handles. See rear grab handle -
hard top
7. Fit rear end trim panel. See rear end trim -
hard top
TRIM CASING - TAIL DOOR
Remove
1. Unscrew 2 bolts and remove grab handle from
rear door.
2. Remove 2 screws and detach wiper motor cover.
3. Remove 7 screws securing trim casing to door.
4. Remove 2 screws and lift wiper motor harness
cover from harness support bracket.
5. Carefully release 8 clips securing trim casing to
door.
6. Remove trim casing and collect door lock cover.
Refit
7. Position door lock cover, fit trim casing and
secure with clips.
8. Fit harness cover and secure with two screws.
9. Secure door panel with retaining screws.
10. Position wiper motor cover and secure with 2
screws.
11. Position grab handle and secure with 2 bolts.
76
CHASSIS AND BODY
18
REPAIR
DOOR LOCK - TAIL DOOR
Remove
1. Remove door trim casing. See trim casing -
tail door
2. Remove screws, washers and nut retainer plate
securing top of lock to door.
3. Remove nuts, washers and stud retainer plate
securing bottom of lock to door.
4. Withdraw lock assembly.
5. Remove door lock gasket.
6. Clean sealant from retainer plates.
7. Insert key into barrel.
8. Depress lock barrel plunger and withdraw barrel
from lock.
Refit
9. Fit new barrel into lock.
10. Apply sealant to lock retainer plates.
11. Fit lock to door with a new gasket.
12. Secure with retainer plates, screws, washers
and nuts.
striker. Adjust striker as necessary. See
Adjustment, Tail door striker - adjust
14. Fit door trim casing. See trim casing - tail
door
CHASSIS AND BODY
19
REPAIR
SUN ROOF
Remove
1. Open sun roof fully.
2. Disengage spring lock from operating handle
catch.
3. Holding sun roof at both sides, release hinges
from locating brackets at front of outer frame.
4. Remove sun roof.
5. Starting from centre rear, peel headlining finisher
from inner frame.
6. Remove 18 screws securing inner frame to outer
frame and detach inner frame.
7. Lift outer frame from roof.
NOTE: Assistance may be required to
remove the sun roof assembly.
Refit
8. Clean roof area around outer frame seating.
9. Position outer frame on roof.
10. Fit inner frame to headlining and secure to outer
frame with 18 screws but do not fully tighten.
11. Check alignment of inner and outer frames with
roof mounting and headlining, adjust as
necessary, and fully tighten fixing screws to 10
Nm, 7 lbf ft.
12. Starting from centre rear, fit headlining finisher
lip into locating channel of inner frame.
13. Press finisher firmly over inner frame and
continue around complete frame, ensuring
finisher lies flat on headlining.
14. Fit sun roof hinges fully into locating brackets on
outer frame, and lower the glass panel.
15. Engage operating handle catch with spring lock
of outer frame and close sunroof.
76
CHASSIS AND BODY
20
REPAIR
INTERIOR MIRROR
Remove
1. Remove retaining screw securing mirror
adjustment arm to mounting slug.
2. Slide adjustment arm up from mounting slug and
remove mirror.
Refit
3. Slide mirror adjustment arm over mounting slug.
4. Secure mirror with retaining screw.
SUN VISORS
Remove
1. Raise sun visor.
2. Remove 2 screws and collect sun visor.
Refit
3. Position sun visor and secure with 2 screws.
CHASSIS AND BODY
21
REPAIR
FRONT HEADLINING - HARD TOP
Remove
1. Remove sun roof headlining finisher.
2. Remove sun visors. See Sun visors
3. Remove interior lamp. See ELECTRICAL,
Repair, Interior lamp
4. Remove 4 retaining screws and detach both A
post trims.
5. Remove caps and unscrew front seat belt fixing
bolts from B/C posts.
6. Carefully prise side trim panel cap fastener from
B/C posts.
7. Carefully prise 2 cap fasteners, from each side,
securing headlining to body at door apertures.
8. Carefully prise out 7 cap fasteners securing front
and rear headlinings to roof.
9. From both sides, pull side trim panel inwards
enough to release rear corners of front
headlining.
10. Lower headlining, disconnect interior lamp
harness plug at A post, and remove headlining
from vehicle.
NOTE: Take care not to bend the
headlining on removal and refitting.
11. Do not carry out further dismantling if
12. Remove interior lamp harness from headlining.
Refit
13. Tape interior lamp harness to headlining.
14. With assistance, raise headlining to roof.
15. Carefully pull side trim panel inwards, on both
sides, and slide headlining behind trim panel.
16. Position front headlining into recess of rear
headlining and secure both to roof mounting
brackets with cap fasteners.
17. Secure both sides of front headlining to body at
door apertures with cap fasteners.
18. Fit side cap fasteners at B/C posts.
19. Secure seat belts to B/C posts and tighten bolts
to 32 Nm, 24 lbf ft. Fit caps to bolts.
20. Fit A post trims.
21. Fit interior lamp. See ELECTRICAL, Repair,
Interior lamp
22. Fit sun visors. See Sun visors
23. Fit sun roof headlining finisher.
76
CHASSIS AND BODY
22
REPAIR
REAR HEADLINING - HARD TOP
Remove
2. Remove side trim panels. See Side trim panel
- hard top
3. Remove rear grab handles. See Rear grab
handle - hard top
4. Remove rear end lining. See Rear end lining
hard top
5. Remove rear interior lamp. See ELECTRICAL,
6. Remove interior roll-over bar. See Interior
roll-over bar - hard top
7. Carefully prise out 7 trim studs securing rear and
front headlining to roof mounting brackets.
8. Release front corners of headlining from cant
rail, on both sides.
9. Pull headlining forwards sufficiently to clear rear
end lining mounting brackets.
10. Release rear corners of headlining from cant rail,
on both sides.
11. Lower rear headlining from roof and remove
from vehicle.
NOTE: Take care not to bend headlining
on removal and refitting.
CHASSIS AND BODY
23
REPAIR
Refit
12. With assistance, position rear headlining to roof
and locate rear corners in cant rail.
13. Push headlining rearwards and position over
rear end lining mounting brackets.
14. Locate front corners of headlining in cant rail.
15. Position front edge of rear headlining over front
headlining and secure with trim studs.
16. Adjust rear headlining to achieve good fit at all
corners.
17. Fit rear interior lamp. See ELECTRICAL,
18. Fit interior roll-over bar. See Interior roll-over
bar - hard top
19. Fit rear end lining. See Rear end lining - hard
top
20. Fit rear grab handles. See Rear grab handle -
hard top
21. Fit side trim panels. See Side trim panel -
hard top
22. Fit rear end trim panels. See Rear end trim
panel - hard top
BONNET LOCK
Remove
1. Open bonnet.
2. Mark position of guide plate and lock to bonnet
platform.
3. Remove 8 screws securing grille.
4. Remove grille.
5. Remove 2 bolts securing guide plate and lock.
6. Remove guide plate.
7. Release spring securing lock to bonnet platform.
8. Slacken clamping bolt securing bonnet release
cable.
9. Remove lock.
Refit
10. Fit spring between lock and bonnet platform.
11. Position lock and guide plate to bonnet platform
and nip up bolts.
12. Position guide plate and lock to position marks
and tighten bolts to 10 Nm. 7 lbf/ft.
13. Fit cable to lock and tighten clamping bolt.
14. Check operation of release cable and adjust if
necessary.
15. Fit grille and tighten securing screws.
16. Close bonnet.
76
CHASSIS AND BODY
24
REPAIR
BONNET RELEASE CABLE
Remove
1. Open bonnet.
2. Remove 8 screws securing grille.
3. Remove grille.
4. Slacken clamping bolt securing bonnet release
cable.
5. Remove cable from lock.
6. Release cable from clip on underside of bonnet
platform.
7. Feed cable through valance.
8. Collect cable grommet.
9. Loosen clamping nut securing bonnet release
pull to mounting bracket.
10. Remove bonnet release pull from mounting
bracket.
11. Withdraw cable through bulkhead.
Refit
12. Feed cable through bulkhead and fit bonnet
release pull to mounting bracket. Tighten
clamping nut.
13. Route cable along inner wing.
14. Feed cable through valance.
15. Fit grommet between cable and valance.
16. Fit cable to securing clip on underside of bonnet
platform.
17. Fit cable to lock and tighten clamping bolt.
18. Check operation of release cable and bonnet
lock and adjust if necessary.
19. Fit grille and tighten screws.
20. Close bonnet.
CHASSIS AND BODY
25
REPAIR
LOWER FASCIA PANEL (HEATER DUCT)
ASSEMBLY
Remove
2. Remove steering wheel. If necessary, use puller
LRT-57-014.
3. Remove 7 screws and lift lift top half of nacelle
from steering column switch assembly.
4. Ease bottom half of nacelle from switch
gaiters/grommets and remove.
5. Remove instrument panel. See INSTRUMENTS,
Repair, Instrument panel
6. Disconnect heater control cable. See HEATING
AND VENTILATION, Repair, Heater control
cable - air distribution
7. Prise out Land Rover decal and remove screw
securing grab handle to crash pad.
8. Remove screw securing grab handle to lower
fascia panel.
9. Lift grab handle to release locating pins from
fascia panel.
76
CHASSIS AND BODY
26
REPAIR
10. Remove 4 screws and remove both demister
vents from crash pad.
11. Remove 3 screws securing crash pad to fascia
bulkhead.
12. Remove crash pad.
13. Remove rear door switch panel. See
ELECTRICAL, Repair, Switch panel-rear door
services
14. Remove 2 screws, washers and nuts securing
auxiliary switch panel to lower fascia panel and
switch cover.
15. Withdraw switch panel and disconnect harness
leads.
16. Remove 2 screws securing switch cover to
parcel tray.
17. Remove air conditioning fascia duct bezel. See
AIR CONDITIONING, Repair, Fascia duct
bezel
18. If air conditioning is not fitted, remove 4 screws
and remove both footwell vents from lower fascia
panel.
19. Remove single screw and detach door check
strap cover from LH and RH doors.
20. Remove 3 screws securing wiper motor cover to
fascia bulkhead.
21. Release locating pins from fascia panel, lower
wiper motor cover and disconnect instrument
ilumination switch plug. Retain wiper motor rack
cover.
22. Remove centre console. See Centre console
23. Prise out 2 large and 5 small cap fasteners
securing trim panel to parcel shelf and fascia
bulkhead.
24. Carefully fold back trim panel to clear fresh air
vent operating levers and remove panel from
parcel shelf.
25. Release demist hose and lift parcel shelf from
lower fascia panel (heater duct). Feed main
harness leads and plugs through aperture in
parcel shelf.
26. Remove parcel shelf.
27. Remove 4 screws securing bottom edge of lower
fascia panel to fascia bulkhead, noting position
of both footwell cover retaining plates. Remove
retaining plates.
28. Unscrew 2 retaining bolts securing top edge of
lower fascia panel to bulkhead.
29. With assistance, release lower fascia panel and
remove from vehicle.
CHASSIS AND BODY
27
REPAIR
Refit
30. Position lower fascia panel to bulkhead and
secure top edge with 2 bolts.
31. Locate RH footwell cover retaining plate under
bottom edge of fascia panel and secure with 3
screws.
32. Repeat operation for LH footwell cover retaining
plate.
33. Fit remaining lower fascia panel fixing screws.
34. Locate parcel shelf. Ensure all rear door services
and auxiliary switch panel harness leads and
plugs are fed through aperture in parcel shelf.
35. Fit demist hoses into heater duct of lower fascia
panel. Ensure flanges of hose grommets are
correctly seated.
36. Fit trim panel and secure with cap fasteners.
37. Fit centre console. See Centre console
38. Reconnect instrument illumination switch plug
and locate wiper motor cover pins in lower fascia
panel and secure wth 3 screws. Ensure wiper
rack cover is correctly seated.
39. Fit door check strap covers on both sides.
40. Fit air conditioning fascia duct bezel. See AIR
CONDITIONING, Repair, Fascia duct bezel
41. If air conditioning is not fitted, fit footwell vents to
lower fascia panel.
42. Fit auxiliary switch cover to parcel tray.
43. Connect leads and plugs to auxiliary switches
and clock.
44. Secure switch panel to lower fascia panel and
switch cover.
45. Fit rear door switch panel. See ELECTRICAL,
Repair, Switch panel-rear door services
46. Fit crash pad to fascia bulkhead.
47. Fit demister vents in crash pad.
48. Fit grab handle to lower fascia panel and secure
to crash pad. Refit Land Rover decal.
49. Connect multi-plugs to rear screen, hazard and
interior lamp switches and fit switch panel to
fascia panel.
50. Fit heater control cable. See HEATING AND
VENTILATION, Repair, Heater control cable -
air distribution
51. Fit instrument binnacle. See ELECTRICAL,
Repair, Instrument binnacle
52. Fit steering column nacelle.
53. Fit steering wheel.
54. Reconnect battery.
FRONT WING [FENDER] ASSEMBLY
Remove
1. Release exterior roll-over bar from its fitted
position to allow removal of front wing [fender].
See exterior roll-over bar
2. Raise and support front of vehicle on safety
stands.
3. Remove road wheel.
4. Disconnect wiring connectors for parking and
indicator lamps.
5. Disconnect harness multiplug for headlamp.
6. Position wiring clear of wheel arch.
7. Inside wing [fender] rear: Loosen fully 3 bolts
securing wing [fender] bulkhead.
8. Remove 2 bolts securing wheel arch to brackets,
front and rear.
9. From inside engine bay: Remove bolt securing
rear of wing [fender] to bulkhead.
10. Remove 2 bolts securing wing [fender] to
bracket, front bottom.
11. Remove 2 bolts securing wing [fender] to
bracket, front top.
12. Lift wing [fender] assembly and disengage rear
from 3 bolts and remove.
Refit
13. Ensure washers are against heads of bolts with
clearance to insert wing [fender].
14. Position and engage rear of wing [fender] onto
bolts.
15. Fit bolts securing top of wing [fender] to front
bracket, do not tighten.
16. Fit bolts securing bottom of wing [fender] to front
bracket, do not tighten.
17. Fit bolts securing wheel arch to brackets, do not
tighten.
18. Position wiring inside wheel arch.
19. Fit bolt securing top of wing [fender] to bulkhead.
20. Align wing [fender] to A post and tighten bolts
inside wing [fender] and at top. 25 Nm, 18 lbf ft.
21. Align front of wing [fender] and tighten bolts at
front. 25 Nm, 18 lbf ft.
22. Tighten bolts inside wheel arch. 25 Nm, 18 lbf ft.
23. Connect wiring.
24. Fit road wheel and lower vehicle, tighten nuts to
130 Nm, 95 lbf ft.
25. Fit exterior roll-over bar. See exterior roll-over
bar
76
CHASSIS AND BODY
28
REPAIR
TRIM CASING - FRONT DOOR SOFT TOP
Remove
1. Prise open 2 finishers and remove 2 screws
securing door pull.
2. Remove 13 screws securing door trim casing.
3. Release trim casing from door, disconnect wires
from speaker and withdraw casing from door
handle.
Refit
4. Ensure screw inserts are in door panel or use
new inserts. Ensure that anti-vibration pads are
in position on trim casing.
5. Position trim casing to door, connect speaker
wiring and engage door handle, align fixings in
door and secure with screws.
6. Fit door pull, secure with screws and insert
finishers.
FRONT DOOR LOCK - SOFT TOP
Remove
1. Remove door casing. See Trim casing - front
door soft top
2. Remove 2 screws, washers and nut retainer
3. Remove 2 nuts, washers and screw retainer
4. Withdraw lock complete from door panel.
7. Insert key into barrel, depress lock barrel plunger
and withdraw lock barrel.
Refit
10. Fit lock to door with a NEW gasket.
and nuts.
striker.
13. Adjust striker as necessary. See Adjustment,
Door lock striker - adjust
14. Refit door casing. See Trim casing - front
door soft top
CHASSIS AND BODY
29
REPAIR
TAIL DOOR LOCK - SOFT TOP
Remove
1. Open tail door.
2. Remove 2 screws, washers and nut retainer
3. Remove 2 nuts, washers and screw retainer
4. Withdraw lock assembly.
7. Insert key into barrel, depress lock barrel plunger
and withdraw barrel from lock.
Refit
10. Fit lock to door with a NEW gasket.
and nuts.
striker.
13. Adjust striker as necessary. See Adjustment,
tail door striker - adjust
PRIVATE LOCK - TAIL DOOR
Remove
1. Remove tail door lock. See Door lock - tail
door
2. Insert key in barrel.
3. Depress lock barrel plunger (seeST1979M).
4. Withdraw barrel from lock.
Refit
5. Reverse removal procedure.
6. Refit tail door lock. See Door lock - tail door
76
CHASSIS AND BODY
30
REPAIR
EXTERIOR ROLL-OVER BAR
Remove
1. Remove torx bolt, from both sides, securing top
of roll-over bar to roof mounted bar.
2. With assistance to support roll-over bar at
windscreen, remove 4 torx bolts, from both
sides, securing roll-over bar to fender mounting.
3. Remove two torx bolts, from both sides, securing
top bar to roof mounting.
4. Slide top bars rearwards to disengage from main
roll-over bar assembly.
5. Lift main roll-over bar assembly from vehicle.
6. If necessary, remove 2 torx bolts and nuts, from
both sides, and detach lower cross bar from
main roll-over bar.
Refit
7. Locate lower cross bar into main roll-over bar
mounting brackets and secure with torx bolts
and nuts to 25 Nm, 18 lbf ft.
8. Ensure rubber gaskets are fitted correctly to
roll-over bar mounting brackets.
9. With assistance, lift roll-over bar assembly and
position on fenders.
10. Slide top bars into main roll-over bar, position on
roof mounting and secure with torx bolts to 25
Nm, 18 lbf ft.
11. Secure roll-over bar to both fender mountings
with torx bolts. Tighten to 25 Nm, 18 lbf ft.
12. Secure top bars to main roll-over bar and tighten
fixing bolts to 25 Nm, 18 lbf ft.
CHASSIS AND BODY
31
REPAIR
INTERIOR ROLL-OVER BAR - HARD TOP
Remove
1. Remove rear seat squabs. See rear seat
squab
2. Remove rear end trim panels. See rear end
3. Remove side trim panels. See side trim panel
- hard top
4. Remove centre console. See Centre console
5. Remove 4 bolts securing centre section of
roll-over bar and seat belt stalks to floor. On
drivers side, disconnect harness plug connector
of audible warning circuit at belt stalk.
6. Remove 2 torx bolts and nuts from both sides
and detach centre section of roll-over bar
assembly.
7. Remove torx bolt, from both sides, securing
roll-over bar to body side mounting brackets.
8. Remove 3 bolts and washers, from both sides,
securing lower roll-over bar brackets to front of
wheelarch.
9. Remove 2 torx bolts and washers, from both
sides, securing roll-over bar upper mountings to
roof fixing brackets and carefully lower complete
assembly to floor.
10. Unscrew retaining bolts, from both sides, and
remove front seat belt inertia reels and rear seat
belts from roll-over bar mounting.
11. Supporting from both sides, raise and tilt
roll-over bar rearwards to clear wheelarches.
12. Remove roll-over bar from vehicle.
NOTE: Assistance may be required to
remove roll-over bar.
76
CHASSIS AND BODY
32
REPAIR
Refit
13. Supporting from both sides, position roll-over
bar, engage struts in rear corners and front of
side panels. Align on floor.
14. Secure front seat belt inertia reels and rear seat
belts to roll-over bar mountings. Tighten bolts to
32 Nm, 24 lbf ft.
15. Raise roll-over bar assembly and secure to roof
mounting brackets. Tighten bolts to 45 Nm, 33
lbf ft.
16. Secure roll-over bar to wheelarches. Tighten
17. Secure roll-over bar to body side mounting
brackets, tightening bolts to 45 Nm, 33 lbf ft.
18. Secure centre section to main roll-over bar, but
do not fully tighten fixing bolts at this stage.
19. Reconnect drivers seat belt audible warning
harness plug.
20. Secure seat belt stalks and roll-over bar floor
mounting brackets to chassis. Tighten bolts to 32
Nm, 24 lbf ft.
21. Fully tighten roll-over bar centre section retaining
22. Fit centre console. See Centre console
23. Fit side trim panel. See Side trim panel
REAR SPEAKER PANEL
Remove
1. Raise seat cushion and fit stowage strap.
2. Remove rear end trim panel. See rear end trim
panel - hard top
3. Remove rear speaker. See ELECTRICAL,
Repair, rear speaker
4. Peel back carpet and remove 2 screws securing
speaker panel to wheelarch.
5. Prise top edge of panel down to release from
body channel.
6. Remove speaker panel.
Refit
7. Position speaker panel on wheel arch.
8. Press top edge of panel down firmly and locate
under body channel.
9. Secure speaker panel to wheel arch with screws
and reposition carpet.
10. Fit rear speaker. See ELECTRICAL, Repair,
rear radio speaker
11. Fit rear end trim panel. See rear end trim
panel - hard top
CHASSIS AND BODY
33
REPAIR
WINDSCREEN GLASS
Remove
1. Remove windscreen wiper arms. See WIPERS
AND WASHERS, Repair, Wiper arm
2. Remove rear view mirror. See Interior rear
view mirror
3. Remove 2 screws from each side and release A
post finishers.
4. Cover windscreen demist vents with tape to
prevent ingress of glass particles.
5. From the outside: Free lip of the sealing rubber
from sealant along top of frame and down each
side.
6. With an assistant supporting the glass from
outside and starting at a top corner, press
windscreen glass outwards and release sealing
rubber from flange.
7. Remove sealing rubber from glass.
WARNING: If glass has splintered, protect
the eyes and use protective gloves.
8. If windscreen has broken, ensure that all
particles of glass are removed. Use a vacuum
cleaner to remove glass from fascia, carpets and
seats.
9. Check frame for distortion and damage to flange,
dress and true flange as necessary. Apply
primer to any bare metal.
10. Remove particles of glass and examine sealing
rubber for cuts and damage, renew as nessary.
Refit
11. Lay glass on felt covered supports, DO NOT
stand on edge.
CAUTION: Any chipping of glass edge may
develop into cracks.
12. Apply a soap solution to glazing channel of
sealing rubber.
13. Align sealing rubber to glass and fit by working
around glass and easing sealing lips over glass
edge.
14. Insert a cord around the flange channel of
sealing rubber so that ends cross over at the
bottom.
15. Apply a soap solution around sealing rubber to
aid fitment.
16. Place glass assembly against frame ensuring
sealing rubber has equal overlap all round with
draw cord over bottom of flange.
17. Assistant from outside, press sealing rubber
firmly against flange and use cord to pull lip of
seal over flange.
18. Carefully work around sealing rubber and
equalize seal to glass and flange.
19. Apply a bead of windscreen sealant under
outside sealing lip, along each side and across
the top.
20. Fit rear view mirror. See Interior rear view
mirror
21. Fit A post finishers.
22. Remove tape from demist vents.
23. Fit windscreen wiper arms. See WIPERS AND
WASHERS, Repair, Wiper arm
76
CHASSIS AND BODY
34
REPAIR
REAR TOW BAR
Remove
1. Remove bolt, washer and nut from both sides,
securing tow bar lower mounting brackets and
towing [fender] eyes to chassis.
2. Remove 4 bolts and spring washers securing
tow bar centre mounting bracket to chassis.
3. Remove both bolts securing 2 tow bar locating
tubes in rear chassis cross member.
4. Remove 2 bolts securing tow bar top mounting
brackets to chassis.
5. With assistance, withdraw tow bar assembly
from chassis.
Refit
6. With assistance, lift tow bar assembly and locate
both tubes in chassis crossmember.
7. Secure top tow bar mounting brackets to chassis
but do not fully tighten fixings.
8. Secure tow bar locating tubes to rear of chassis
and tighten bolts to 25 Nm, 18 lbf ft.
9. Secure tow bar centre mounting bracket to
underside of chassis and tighten bolts to 25 Nm,
18 lbf ft.
10. Position towing [fender] eyes to lower mounting
brackets and secure to chassis and tighten bolts
11. Fully tighten tow bar top mounting bracket bolts
CHASSIS AND BODY
35
REPAIR
BONNET
Remove
1. Remove split [cotter] pin from bonnet prop lower
pivot.
2. Remove washer and anti-rattle washer from
pivot.
3. Position suitable chock to support bonnet in a
position to gain access to hinge nuts.
4. Release bonnet prop from pivot, fold prop up into
bonnet and rest bonnet onto chock.
5. Mark outline of hinge on bonnet.
6. Remove 6 nuts and screws securing bonnet to
hinges.
7. With assistance, remove bonnet.
Refit
8. With assistance, position bonnet to hinges.
9. With assistance, fit screws through hinges and
bonnet and fit washers and nuts to screws.
10. Align hinges to bonnet markings.
11. Tighten hinge retaining screws.
12. Raise bonnet from chock and connect prop to
pivot.
13. Fit anti-rattle and plain washers to pivot and
secure with split [cotter] pin.
14. Release prop and close bonnet to check
alignment and operation.
76
CHASSIS AND BODY
36
REPAIR
CENTRE CONSOLE
Remove
1. Open cubby box lid.
2. Remove in-car entertainment unit - if fitted.
3. Remove 6 screws securing cubby box to
console.
4. Remove cubby box.
5. Release rear edge of selector housing surround.
6. Remove surround.
7. Release hi-low gear lever gaiter from console.
8. Remove hi-low gear lever knob and gaiter
assembly.
9. Remove tray from console.
10. Remove screw securing front edge of console.
11. Remove 3 screws securing rear of console.
12. Remove console.
Refit
13. Fit and align console.
14. Fit and tighten screws securing console.
15. Fit tray to console.
16. Fit hi-low gear lever knob and gaiter assembly.
17. Secure hi-low gear lever gaiter to console.
18. Fit gear selector housing surround and secure.
19. Fit cubby box to console and secure with
screws.
20. Fit in-car entertainment unit - if fitted.
21. Close cubby box lid.
CHASSIS AND BODY
37
REPAIR
RADIATOR GRILLE
Remove
1. Remove 8 screws securing grille to front panel.
2. Remove radiator grille
Refit
3. Position radiator grille to front panel.
4. Secure grille with screws.
GRILLE PANEL
Remove
1. Remove radiator grille. See radiator grille
2. Disconnect multiplug from condenser fan
fly-lead.
3. Loosen bolts securing top panel and grille panel
to fenders.
4. Remove bolts securing securing grille panel to
fenders.
5. Remove grille panel.
Refit
6. Position grille panel and fit bolts to fender, finger
tight.
7. Fit plastic nuts to lower fixing, each side
8. Fit screws to top panel.
9. Align grille panel and tighten all fixings.
10. Fit radiator grille. See radiator grille
76
CHASSIS AND BODY
38
REPAIR
CANOPY ASSEMBLY
Remove
1. Release side window velcro strips, each side
and top.
2. Unzip side window panels, at side only.
3. Release retaining batten from bottom channel.
4. Open rear door.
5. Release velcro strips each side of rear window.
6. Unzip rear window panel, down each side.
7. Release retaining bar, each end of rear window.
8. Release velro strips securing 2 flaps to roof bow.
9. Release 5 press studs securing flap around
centre roll-over bar.
10. Release 5 press studs securing straps around
rear roll-over bar.
11. Open front doors. Release 2 press studs
securing flaps, forward of centre roll-over bar.
12. Release 3 press studs securing flaps to frame
above front doors.
13. Release 3 canopy battens from channels at
each rear corner panel.
14. Release canopy batten from channel on each
side panel.
CHASSIS AND BODY
39
REPAIR
15. Remove screw securing side panel support rod
to vehicle body on each side.
16. Unhook top end of rods from support bars.
17. Remove top of side panels from groove in side
bar mouldings.
18. Withdraw suppotr rods from pockets in side
panels.
19. Release 2 press studs securing canopy to each
end of windscreen frame.
20. Pull canopy forward to release tension.
21. Release batten from channel above windscreen
and ease dowwards to clear.
22. Ease front of canopy up between frame and
roll-over bar brackets.
23. Fold front of canopy onto roof.
24. Fold rear panel onto roof of canopy.
25. Fold each side panel onto roof.
26. Fold side and rear corner panels onto roof.
27. Remove canopy from vehicle.
28. Remove intermediate roof bow, retained by
spring loaded ball each side.
Refit
29. Lubricate spigots and fit intermediate bow to
cant rails.
30. Position canopy across centre roll-over bar and
roof bow.
31. Unfold canopy, position loosely over roll-over
bars and centralise.
32. Pull forward and position retaining batten
between windscreen frame and roll-over bar.
33. Ease batten upwards, rotate and engage
channel, press ends down and fully into channel.
34. Fasten front of canopy with press studs.
35. Pull canopy to tension over rear roll-over bar.
36. Fasten press studs securing canopy to rear
roll-over bar.
37. Feed cut-out in top of side panel into grove
around roll-over bar moulding.
38. Fasten press studs securing front sides to
support bars.
39. Fasten press studs securing canopy to centre
roll-over bar.
40. Secure flaps to roof bow.
41. Fully tension straps securing canopy to rear
roll-over bar.
42. If side windows have been removed: Zip side
windows along top only.
43. Engage side window zips at each side, do up 50
mm, 2 in only.
76
CHASSIS AND BODY
40
REPAIR
44. Pull down on rear panels and engage battens by
pressing firmly into place.
NOTE: Use a T handled hook to pull down
on the loops to ease batten engagement.
45. Fasten side window zips and secure velcro
strips.
46. Fit rear window retaining bar, fasten rear window
zips and secure velcro strips.
HEATING AND VENTILATION
1
HEATING AND VENTILATION SYSTEM
Description
The heating and ventilation system is standard on all
models. Air conditioning is an optional system which
provides fully integrated climate control for the vehicle
interior.
The heater assembly, comprising a matrix housed in a
distribution unit and a variable speed blower motor, is
located on one side of the engine compartment and
attached directly to the fascia bulkhead.
The heating controls are positioned on the outside of
the instrument binnacle and cable linked to
mechanical flaps in the distribution unit.
Heater assembly
1. Heater distribution unit
2. Fixings, heater to fascia bulkhead
3. Heater matrix
4. Blower motor housing
5. Circlip, impeller to blower motor
6. Impeller
7. Resistor unit and harness connector
8. Fixings, blower motor mounting plate
9. Mounting plate, blower motor
10. Blower motor
11. Fixings, blower motor to mounting bracket
12. Temperature flap, air flow to heater matrix
13. Air flap, air supply to plenum chamber (heater
duct)
80
2
HEATER OPERATION
The heater matrix, located in the distribution unit, is
connected to the engine cooling system. As coolant is
circulated continuously through the matrix, a selection
of heated or ambient air is controlled by two flaps
within the distribution unit.The temperature flap
controls the amount of ambient air to the heater
matrix, air being supplied
through a ducted vent on top of the vehicle front wing
to the blower motor (volute) housing. The blower
motor can be used to boost the air flow into the
distribution unit. The air flap controls the supply of
heated or ambient air from the heater unit into a
plenum chamber integeral with the vehicle fascia. Two
flaps in the plenum chamber (heater duct) distribute
the air flow to either the footwell vents or windscreen
demister vents.
Non air conditioning fascia shown
Heater controls
1. Temperature control
Move the lever downwards to increase air
temperature or up to decrease air temperature.
2. Air distribution control
Lever fully up - windscreen vents only.
Lever midway - footwell and windscreen vents.
Lever fully down - footwell vents.
3. Blower motor fan speed control
Move the lever progressively downwards to increase
fan speed. With the control at O the fan is switched
off and the volume of air entering the passenger
compartment is solely dependent on ram effect when
the vehicle is moving forward.
3
Fresh air vents
Two fresh air vents are fitted in the windscreen frame
and are controlled independently of the vehicle
heating system. Each vent is operated separately.
To open a vent, push the lever to the right and then to
the required position.
1
REPAIR
HEATER UNIT
Remove
1. Remove bonnet and disconnect battery.
2. Remove radiator bottom hose at radiator union
and drain cooling system. See COOLING
SYSTEM, Adjustment, Drain and refill
3. Slacken clips and disconnect heater hoses at
heater box unions.
4. Remove outer cable securing clips.
5. Slacken trunnions and disconnect control cables
from heater vent flap levers.
6. Remove heater wiring harness securing loop.
7. Disconnect harness multi-plug.
8. Remove interior bulkhead trim.
9. Remove lower nuts and bolts securing the
heater unit to the bulkhead. If air conditioning is
fitted, remove evaporator. See AIR
CONDITIONING, Repair, Evaporator
10. Slacken heater unit upper retaining bolts.
11. Manoeuvre heater unit, complete with blower
motor, clear of air inlet duct and remove from
engine compartment.
12. Remove sealing rubber.
For heater matrix removal. See Heater matrix
For blower motor removal. See Blower motor
Refit
13. Smear a NEW sealing rubber with a suitable
impact adhesive and fit to heater unit.
14. Manoeuvre heater unit into position in engine
compartment, fit blower motor to air inlet duct
and locate upper fixing bolts.
15. Loosely fit lower fixing bolts to heater unit .
16. Fully tighten upper fixing bolts followed by the
lower fixings.
17. Refit interior bulkhead trim.
18. Secure wiring harness and reconnect multi-plug.
19. Fit control cables to vent flap trunnions and
secure with outer cable clips.
20. Connect heater hoses.
21. Fit radiator bottom hose and refill cooling
system. See COOLING SYSTEM, Adjustment,
Drain and refill
22. If air conditioning is installed, fit evaporator. See
AIR CONDITIONING, Repair, Evaporator
23. Fit bonnet and reconnect battery.
80
2
REPAIR
BLOWER MOTOR
Remove
1. Remove heater unit. See Heater unit
2. Remove 3 nuts securing angled bracket to
heater unit. Pivot bracket to remove from studs.
3. Remove 5 nuts securing blower motor assembly
to volute housing.
4. Disconnect harness connector and remove
blower motor from volute housing.
5. Release circlip and withdraw impeller from motor
drive shaft.
6. Remove 3 nuts securing blower motor to
mounting plate.
7. Remove blower motor.
8. Examine components for signs of wear and
renew as necessary.
Refit
9. Apply Bostik 1261 adhesive to mating faces of
mounting plate and blower motor.
10. Fit blower motor to mounting plate and secure
with nuts. Ensure rubber mountings are correctly
fitted.
11. Fit impeller to motor drive shaft and secure with
circlip.
12. Position blower motor assembly in volute
housing and secure with nuts. Fit angled bracket
to lower fixing.
13. Reconnect harness plug to resistor harness and
fit angled bracket to heater unit.
14. Fit heater unit. See Heater unit
HEATER MATRIX
Remove
2. Remove 3 nuts securing angled bracket to
heater unit. Pivot bracket to remove from studs.
3. Remove 14 screws and detach 2 matrix retaining
plates from heater unit base.
4. Remove 9 screws securing matrix top retaining
plate.
5. Withdraw heater matrix through top of heater
unit casing.
3
REPAIR
Refit
6. Fit foam rubber to heater matrix casing.
7. Position matrix in heater unit casing.
8. Check that both vent flaps operate correctly
without sticking.
9. Secure matrix top retaining plate.
10. Secure matrix bottom retaining plates.
RESISTOR UNIT
Remove
2. Drill out 4 rivets securing resistor mounting plate
to top of volute housing.
3. Remove resistor and disconnect blower motor
plug from harness.
Refit
4. Apply Bostik adhesive to resistor mounting plate
and rivet to volute housing.
5. Reconnect blower harness motor plug.
HEATER CONTROL CABLE - TEMPERATURE
CONTROL
Remove
2. Remove 4 screws securing instrument binnacle
to fascia cowl.
3. Pull instrument binnacle away from fascia to
ease access to control cable at bulkhead.
4. Remove retaining screws and pull off air
distribution and temperature control lever knobs.
5. Remove 3 screws and detach side cover,
complete with control lever assembly.
80
4
REPAIR
6. Remove 2 screws securing control lever
assembly to side cover and remove cover.
Retain plastic screw spacers fitted between
cover and control lever assembly.
7. Remove bolt and release outer cable retaining
clip.
8. Slacken grub screw and release inner cable from
clevis.
9. From inside engine compartment: Release outer
cable retaining clip at heater unit.
10. Slacken trunnion fixing and release inner cable
from heater unit flap lever.
11. Release 2 retaining clips securing control cables
to engine bulkhead.
12. Pull control cable through bulkhead grommet
and remove from vehicle.
Refit
13. Fit control cable to heater flap lever trunnion with
approximately 10 mm, 0.4 in of inner cable
protruding from trunnion. Fully tighten trunnion.
14. Secure outer cable with retaining clip.
15. Route control cable through sealing grommet
and along inside of engine bulkhead to fascia
binnacle.
16. Secure control cables to engine bulkhead with
retaining clips.
17. With control lever in closed position, fit inner
cable to lever clevis and fully tighten clevis grub
screw.
18. Fit outer cable retaining clip and fully tighten
securing bolt.
19. Fit side cover to control lever assembly. Ensure
fixing screw spacers are positioned between
cover and lever assembly.
20. Fit side cover to fascia.
21. Fit control lever knobs.
22. Fit instrument binnacle.
5
REPAIR
HEATER CONTROL CABLE - AIR DISTRIBUTION
Remove
2. Remove steering wheel.
3. Remove steering column nacelle.
INSTRUMENTS, Repair, Instrument panel
5. Remove retaining screws and pull off air
distribution and temperature control lever knobs.
6. Remove 3 screws and detach side cover,
complete with control lever assembly.
assembly to side cover and remove cover.
Retain plastic screw spacers fitted between
cover and control lever assembly.
8. Remove bolt and release outer cable retaining
clip.
9. Slacken grub screw and release inner cable from
clevis.
10. Remove heater duct assembly. See CHASSIS
AND BODY, Repair, Heater duct assembly
11. Remove 19 screws and lift off heater duct cover.
12. Slacken vent flap trunnion fixing, release air
distribution control cable and remove from
heater duct.
13. Check condition of foam sealant on heater duct
cover and renew if necessary.
Refit
14. Fit control cable through heater duct cover and
secure to vent flap trunnion. Bend over cable
end to fully secure.
15. Fit heater duct cover.
16. Fit heater duct assembly to fascia bulkhead.
See CHASSIS AND BODY, Repair, Heater
duct assembly
17. Route control cable along fascia bulkhead to
contol lever assembly.
18. With control lever in closed position, secure
cable to clevis.
19. Fit outer cable retaining clip to lever assembly.
20. Fit lever assembly to side cover. Ensure screw
spacers are fitted between cover and lever
assembly.
21. Fit side cover to fascia cowl.
22. Fit control lever knobs.
80
6
REPAIR
CONTROL CABLE AND BLOWER MOTOR SWITCH
Service repair no - 80.10.17 - Control cable
Service repair no - 80.10.22 - Blower motor switch
Remove
2. From inside engine compartment, release outer
cable retaining clip at heater unit.
3. Slacken trunnion fixing and release inner cable
from heater unit flap lever.
4. Release 2 retaining clips securing control cables
to engine bulkhead and heater hoses.
5. Remove 4 screws securing instrument panel to
fascia cowl.
6. Pull instrument binnacle away from fascia to
ease access to control cable.
assembly to side of fascia binnacle cowl. Retain
plastic screw spacers fitted between cowl and
lever assembly.
8. Release lever assembly and disconnect 3
blower motor leads, noting their positions.
9. Pull control cable through bulkhead grommet
and out from instrument binnacle cowl.
10. Release retaining clip securing outer cable to
lever assembly.
11. Release inner cable from lever peg.
NOTE: Renew complete lever assembly if
the blower motor switch is faulty.
Refit
12. Fit control cable to lever assembly peg.
13. Fit retaining clip to secure outer cable.
14. Reconnect blower motor leads.
15. Route cable to rear of instrument panel cowl,
along bulkhead and out through grommet into
engine compartment.
16. Fit lever assembly to instrument panel cowl.
Ensure screw spacers are fitted between cowl
and lever assembly.
17. Fit instrument binnacle to fascia cowl.
18. With lever in closed position, fit control cable to
heater unit flap lever trunnion.
19. Secure outer cable with retaining clip.
20. Secure control cables to engine bulkhead and
heater hoses with retaining clips.
AIR CONDITIONING
1
SCHEMATIC LAYOUT OF THE AIR CONDITIONING
SYSTEM
1. Compressor
2. Condenser
3. Receiver/drier
4. Thermostatic expansion valve
5. Evaporator
6. Capillary tube
7. Trinary pressure switch
8. Condenser cooling fan - single only
9. Compressor high pressure relief valve
10. Sight glass - refrigerant
11. Drying agent - receiver/drier
12. Blower motor
A1 Ambient air flow through condenser
A2 Recirclatory air flow through fan and evaporator
A3 Cooled air flow to vehicle interior
F1 High pressure high temperature refrigerant
vapour
F2 High pressure slightly subcooled refrigerant
liquid
F3 High pressure slightly subcooled refrigerant
liquid with moisture, vapour bubbles and foreign
matter removed
F4 Low pressure low temperature mixed liquid and
vapour
F5 Low pressure slightly super heated refrigerant
vapour
82
AIR CONDITIONING
2
AIR CONDITIONING SYSTEM OPERATION
The air conditioning system provides the means of
supplying cooled and dehumidified, recirculated air to
the interior of the vehicle. The cooling effect is
obtained by blowing air through the matrix of an
evaporator unit which has a variable temperature
control to provide the conditions required inside the
vehicle. The volume of cooled air supplied is
controlled by a variable speed blower.
A sealed system, charged with Refrigerant R134a,
together with a blower unit and evaporator
temperature control combine to achieve the cooled air
condition.
The air conditioning system comprises six major units:
1. An engine-mounted compressor.
2. A condenser mounted in front of the radiator.
3. A receiver/drier unit mounted on RH front
valance.
4. Thermostatic expansion valve mounted in front
of the evaporator.
5. An evaporator and blower unit mounted under
the RH side of the fascia panel.
6. Blower and temperature control switches.
These units are interconnected by hoses and pipes
carrying Refrigerant R134a, the evaporator is
seporate from the vehicle ventilation system.
Refrigeration cycle
1. Compressor
The compressor (1), belt driven from the crankshaft
pulley, is brought into operation by an AC switch on
the fascia which when selected engages an
electro-magnetic clutch to operate the compressor,
which pressurises and circulates the refrigerant
through the system. The electro-mechanical clutch
maintains the correct temperature and pressure by
engaging or disengaging to support the systems
requirements. The clutch action is normally controlled
by a thermostat located at the evaporator (5). The
compressor is of the swashplate type, having fixed
displacement.
Should the temperature at the evaporator (5) fall low
enough for ice to begin to form on the fins, the
thermostat disengages the clutch and also isolates the
cooling fans relays. When the temperature at the
evaporator rises to the control temperature, the clutch
is re-engaged.
Should the system pressure become excessive or
drop sufficiently to cause damage to the compressor
(1) a trinary pressure switch (7), located in the high
pressure line, signals the relay unit to disengage the
clutch. The compressor also has an emergency high
pressure relief valve (9) fitted.
The condenser cooling fan operates continuously
when air conditioning is selected.
2. Condenser
From the compressor, hot high pressure vaporised
refrigerant (F1) passes to the condenser (2), which is
mounted in front of the engine coolant radiator. Ram
air (A1) passing through the condenser (2),
supplemented by the cooling fan (8) mounted in front
of the condenser, cools the refrigerant vapour
sufficiently to form a high pressure slightly subcooled
liquid (F2).
3. Receiver/drier
This liquid then passes to a receiver/drier (3) which
fulfils two functions. It acts as a reservoir and moisture
extractor (11).
A sight glass (10), in the high pressure line, provides a
method of determining the state of the refrigerant
without breaking into the system.
4. Expansion valve
From the receiver/drier (3) the moisture free high
pressure liquid refrigerant (F3) passes through a
thermostatic expansion valve (4). A severe pressure
drop occurs across the valve and as the refrigerant
enters the evaporator space at a temperature of
approximately -5C, 23F it boils and vaporises.
AIR CONDITIONING
3
5. Evaporator
As this change of state occurs, a large amount of
latent heat is absorbed. The evaporator is therefore
cooled and as a result heat is extracted from the air
flowing across the evaporator. The air flow is
controlled by the blower fans which can be operated
at various speeds.
To prevent liquid passing through to the compressor,
a capillary tube (6), attached to the outlet pipe of the
evaporator (5) and connected to the thermostatic
expansion valve (4), controls the amount that the
valve opens and closes in relation to the temperature
of the low pressure high temperature refrigerant
vapour (F4) at the outlet. The atomised refrigerant
then passes through the evaporator (5). Fan blown air
(A2) passes through the matrix (A3) of the evaporator
and is cooled by absorption due to the low
temperature refrigerant passing through the
evaporator.
A thermostat is positioned in the airflow leaving the
evaporator to sense the temperature of the exterior
fins. Should ice begin to form, due to a too cold
condition, it will signal to disengage the
electro-mechanical clutch on the compressor (1).
From the evaporator, low pressure, slightly
superheated refrigerant (F5) passes to the
compressor to complete the cycle.
AIR CONDITIONING CONTROL SYSTEM
The air conditioning control system comprises relays,
thermostat, pressure switches, and a control panel.
Together these controls, in conjunction with the
cooling fan, compressor clutch and blower, enable
minimal input to maintain the required environment
inside the vehicle.
Selecting air conditioning provides the added facility of
cooled air available to be mixed with warm air from
the heater system to give the required interior
environmental conditions.
Trinary pressure switch
This switch, located in the high pressure line between
the receiver drier and the expansion valve, monitors
refrigerant pressure and by means of the relay
controls the following system functions:
1. Refrigerant pressure drops below 2.0 bar, 29
lbf/in
2
(due to possible leakage), the
compressors electro-mechanical clutch is
dis-engaged.
2. When pressure rises above 2.0 bar, 29 lbf/in
2
the
compressors clutch is re-engaged.
3. Refrigerant pressure rises above 32 bar, 455
lbf/in
2
(due to possible blockage), even with
cooling fan operation, the compressors
electro-mechanical clutch is dis-engaged.
When the pressure drops below 26 bar, 375
lbf/in
2
the compressor clutch is re-engaged.
Condenser cooling fan
The condenser cooling fan operates automatically
whenever the air conditioning system is switched on.
1. Blower control
The blower can be operated at various speeds by
turning the blower switch to the required position.
When the blower is switched off, the air conditioning
system will not operate.
2. Temperature control
Rotate the temperature control switch clockwise to
increase the cooling effect. Use in conjuction with the
blower control as required.
AIR CONDITIONING
1
FAULT DIAGNOSIS
REFRIGERATION SYSTEM FAULTS
For any refrigeration system to function properly all
components must be in good working order. The unit
cooling cycle and the relationship between air
discharge temperature and ambient temperature and
the pressures at the compressor can help to
determine proper operation of the system.
The length of any cooling cycle is determined by such
factors as ambient temperature and humidity,
thermostat setting, compressor speed and air leakage
into the cooled area, etc. With these factors constant,
any sudden increase in the length of the cooling cycle
would be indicative of abnormal operation of the air
conditioner.
The low and high side pressures at the compressor
will vary with changing ambient temperature, humidity,
in-car temperature and altitude.
The following items should be checked before
operating the system:
1. Compressor drive belt tension.
2. Compressor magnetic clutch operation.
3. Condenser fan operation.
4. Condenser fins, dirt will cause poor cooling and
higher operating temperatures.
System check
The following conditions should be checked after
operating the system for several minutes:
1. All high pressure lines and components should
be hot to the touch.
2. All low pressure lines should be cool to the
touch.
3. Inlet and outlet temperatures at the receiver/drier
should be at the same temperature (warm). Any
very noticeable temperature difference indicates
a blocked receiver/drier.
4. Heavy frost on the inlet to the expansion valve
may indicate a defective valve or moisture in the
system.
5. Evaporation air temperature will vary with
ambient temperature and humidity. As humidity
increases the outlet temperature will be higher.
AIR CONDITIONING
1
ADJUSTMENT
GENERAL PRECAUTIONS
The refrigerant used in the air conditioning system is
HFC (Hydrofluorocarbon) R134a.
WARNING: R134a is a hazardous liquid
and when handled incorrectly can cause
serious injury. Suitable protective clothing
must be worn when carrying out servicing
operations on the air conditioning system.
WARNING: R134a is odourless and
colourless. Do not handle or discharge in
an enclosed area, or in any area where the
vapour or liquid can come in contact with naked
flame or hot metal. R134a is not flammable, but
can form a highly toxic gas.
WARNING: Do not smoke or weld in areas
where R134a is in use. Inhalation of
concentrations of the vapour can cause
dizziness, disorientation. uncoordination,
narcosis, nausea or vomiting.
WARNING: Do not allow fluids other than
R134a or compressor lubricant to enter the
air conditioning system. Spontaneous
combustion may occur.
WARNING: R134a splashed on any part of
the body will cause immediate freezing of
that area. Also refrigerant cylinders and
replenishment trolleys when discharging will
freeze skin to them if contact is made.
WARNING: The refrigerant used in an air
conditioning system must be reclaimed in
accordance with the recommendations
given with a Refrigerant Recovery Recycling
Recharging Station.
NOTE: Suitable protective clothing
comprises: Wrap around safety glasses or
helmet, heatproof gloves, rubber apron or
waterproof overalls and rubber boots.
REMEDIAL ACTIONS
1. If liquid R134a strikes the eye, do not rub it.
Gently run large quantities of eyewash over the
eye to raise the temperature. If eyewash is not
available cool, clean water may be used. Cover
eye with clean pad and seek immediate medical
attention.
2. If liquid R134a is splashed on the skin run large
quantities of water over the area as soon as
possible to raise the temperature. Carry out the
same actions if skin comes into contact with
discharging cylinders. Wrap affected parts in
blankets or similar material and seek immediate
medical attention.
3. If suspected of being overcome by inhalation of
R134a vapour, seek fresh air. If unconscious,
remove to fresh air, apply artificial respiration
and/or oxygen and seek immediate medical
attention.
NOTE: Due to its low evaporating
temperature of -30C, -22F R134a should
be handled with care.
WARNING: Do not allow a refrigerant
container to be heated by a direct flame or
to be placed near any heating appliance. A
refrigerant container must not be heated above
50C, 122F.
WARNING: Do not leave a container of
refrigerant without its cap fitted. Do not
transport a container of refrigerant that is
unrestrained, especially in the boot of a car.
82
AIR CONDITIONING
2
ADJUSTMENT
SERVICING PRECAUTIONS
Care must be taken when handling refrigeration
system components. Units must not be lifted by their
hoses, pipes or capillary lines. Hoses and lines must
not be subjected to any twist or stress. Ensure that
hoses are positioned in their correct run before fully
tightening the couplings, and ensure that all clips and
supports are used. Torque wrenches of the correct
type must be used when tightening refrigerant
connections to the stated value. An additional spanner
must be used to hold the union to prevent twisting of
the pipe.
Before connecting any hose or pipe ensure that
refrigerant oil is applied to the seat of the new 0 ring
but not to the threads.
Check the oil trap for the amount of oil lost.
All protective plugs on components must be left in
place until immediately prior to connection.
The receiver/drier contains desiccant which absorbs
moisture. It must be positively sealed at all times.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
Use alcohol and a clean cloth to clean dirty
connections. Ensure that all new parts fitted are
marked for use with R134a.
Refrigerant oil
Use the approved refrigerant lubricating oil - Nippon
Denso ND-OIL 8.
CAUTION: Do not use any other type of
refrigerant oil.
Refrigerant oil easily absorbs water and must not be
stored for long periods. Do not pour unused oil back
into the container.
When renewing system components, add the
following quantities of refrigerant oil:
Condenser 40ml, 1.4 fl oz ............................................
Evaporator 80ml, 2.8 fl oz ............................................
Pipe or hose 20ml, 0.7 fl oz ..........................................
Receiver/drier 20ml, 0.7 fl oz ........................................
Total refrigerant oil in system = 180ml, 6.3 fl oz
A new compressor is sealed and pressurised with
Nitrogen gas. Slowly release the sealing cap, gas
pressure should be heard to release as the seal is
broken.
NOTE: A new compressor should always
have its sealing caps in place and these
must not be removed until immediately
prior to fitting
Fitting a new compressor
A new compressor is supplied with an oil fill (X) of
180ml, 5.3 fl oz.
A calculated quantity of oil must be drained from a
new compressor before fitting.
To calculate the quantity of oil to be drained:
1. Remove sealing plugs from the OLD
compressor.
2. Invert compressor and gravity drain oil into
measuring cylinder. Rotating the compressor
clutch plate will assist complete draining.
3. Note the quantity of oil drained (Y).
4. Calculate the quantity (Q) of oil to be drained
from the NEW compressor using the following
formula:
X - (Y + 20ml, 0.7 fl oz) = Q
Rapid refrigerant discharge
When the air conditioning system is involved in
accident damage and the circuit is punctured, the
refrigerant is discharged rapidly. The rapid discharge
of refrigerant will also result in the loss of most of the
oil from the system. The compressor must be
removed and all the remaining oil in the compressor
drained and refilled as follows:
1. Gravity drain all the oil, assist by rotating the
clutch plate (not the pulley).
2. Refill the compressor with 130ml, 4.6 fl oz of
new refrigerant oil.
3. Plug the inlet and outlet ports.
Servicing Equipment
The following equipment is required for full servicing
of the air conditioning system.
Recovery, recycling and charging station
- Leak detector
- Thermometer +20C to -60C, 70F to -70F
- Safety goggles and gloves
AIR CONDITIONING
3
ADJUSTMENT
REFRIGERANT RECOVERY, RECYCLING,
RECHARGING
WARNING: The air conditioning system is
charged with a high pressure, potentially
toxic refrigerant. Repairs or servicing must
only be carried out by an operator familiar with
both the vehicle system and the charging and
testing equipment.
All operations must be carried out in a
well-ventilated area away from open flame and
heat sources.
Always wear safety goggles and gloves when
opening refrigerant connections.
WARNING: Wear eye and hand safety
protection. Open connections slowly in
case liquid or pressure is present. Allow to
bleed off slowly.
CAUTION: Overcharging air conditioning
system will cause excessive head
pressure.
An air conditioning portable Refrigerant Recovery
Recycling Recharging Station for use with R134a
refrigerant incorporates all the features necessary to
recover refrigerant R134a from the air conditioning
system, to filter and remove moisture, to evacuate and
recharge with the reclaimed refrigerant. The unit can
also be used for performance testing and air
conditioning system analysis.
The operator must adhere to the equipment
Recovery and recycling
1. Connect a Refrigerant Station to the high and
low pressure servicing connections.
2. Operate the refrigerant recovery system
according to the manufacturers instructions.
3. Measure the amount of oil discharged from the
system. Add an equal amount of new refrigerant
oil to compressor before evacuation sequence.
WARNING: Refrigerant must always be
recycled before reuse, to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system. Recycling
should always be carried out with equipment
which is design certified by Underwriter
Laboratory Inc. for compliance with SAE-J1991.
Other equipment may not recycle refrigerant to
the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and commercial
sources must not be used in motor vehicle air
conditioning systems.
Evacuation and recharging
1. Add refrigerant oil to compressor if necessary.
2. Renew the receiver/drier.
CAUTION: When a major repair has been
carried out, a leak test should be carried
out using inert gas.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
82
AIR CONDITIONING
4
ADJUSTMENT
4. Operate the refrigerant evacuation system
according to the manufactures instructions.
NOTE: If the vacuum reading is below 700
mm Hg, 28 in Hg after 15 minutes, suspect
a leak in the system. Partially recharge the
system and check for leaks using an electronic
leak tester. Check suction lines first, then run the
compressor for 5 minutes and then check the high
pressure lines.
CAUTION: The system must be Evacuated
immediately before recharging
commences. Delay between Evacuation
and Recharging is not permitted.
5. Operate the refrigerant recharging system
according to the manufacturers instructions.
Refrigerant to charge system = 900 30gm, 32
1 oz.
6. If the full charge has not been accepted by the
system, start the engine and run it at 1500
rev/min for a minimum of 2 minutes.
Switch on the air conditioning system, open the
vehicle windows, set the temperature control to
cold and switch the blower to maximum speed.
7. Consult Refrigerant Station Manual for correct
procedure to complete the charge.
8. Carry out the air conditioning system
performance test.
LEAK TEST SYSTEM
The following instructions refer to an electronic type
Refrigerant Leak Detector for use with R134a, which
is the safest and most sensitive.
CAUTION: When a major repair has been
carried out, a leak test should be carried
out using an inert gas (see below).
1. Place the vehicle in a well ventilated area but
free from draughts, as leakage from the system
could be dissipated without detection.
2. Follow the instructions issued by the
manufacturer of the particular leak detector
being used.
3. Commence searching for leaks by passing the
detector probe around all joints and components,
refrigerant gas is heavier than air.
4. Insert the probe into an air outlet of the
evaporator or into the evaporator drain tube.
Switch the air conditioning blower on and off at
intervals of ten seconds. Any leaking refrigerant
will be gathered in by the blower and detected.
5. Insert the probe between the magnetic clutch
and compressor to check the shaft seal for
leaks.
6. Check all service valve connections, valve plate,
head and base plate joints and back seal plate.
7. Check the condenser for leaks at the pipe
unions.
8. If any leaks are found, the system must be
discharged before rectification.
9. Rectify any leaks and recheck for leaks during
evacuation prior to charging.
Leak test using inert gas
Use Nitrogen or Helium gas.
1. Connect gas line to recharging station.
2. Pressurise system to 3 bar, 45 lbf/in
2
.
3. Carry out leak test as above.
AIR CONDITIONING
5
ADJUSTMENT
AIR CONDITIONING SYSTEM - PERFORMANCE
TEST
WARNING: R134a is hazardous See
Repair, General Precautions .
Carry out this test with bonnet and doors or windows
open, air conditioning switched on, temperature
control set to cold and blower at maximum speed. Set
the air supply control to supply fresh air.
1. Close low pressure valve on refrigerant station.
2. Close high pressure valve on refrigerant station.
4. Insert dry bulb thermometer into cold air outlet
and position dry and wet bulb thermometer close
to outside air inlet.
Do not spill water from the wet thermometer
(psychrometer).
5. Start engine and run it at 1500 rev/min for 10
minutes with air conditioning switched on.
6. Read both pressure gauges and thermometers.
Check readings against table below with
humidity between 60% and 80%.
7. Switch off air conditioning, stop engine,
disconnect test equipment.
Performance range
Intake temperature Outlet temperature Low pressure High pressure
68 F 41 - 50f 20 - 23 lbf/in
2
116 - 190 lbf/in
2
20 C 5 - 10C 1.4 - 1.6 bar 8.0 - 13 bar
75F 45 - 60F 21 - 28 lbf/in
2
130 - 200 lbf/in
2
25C 7 - 15C 1.5 - 2.0 bar 9.0 - 14 bar
85F 46 - 68F 26 - 40 lbf/in
2
190 - 230 lbf/in
2
30C 8 - 20C 1.8 - 2.8 bar 13 - 16 bar
95F 52 - 72F 36 - 52 lbf/in
2
230 - 270 lbf/in
2
35C 11 - 22C 2.5 - 3.5 bar 16 - 19 bar
Table 1
Ambient Compound Gauge High Pressure
Temperature Readings Gauge Readings
C F bar lbf/in
2
bar lbf/in
2
16 60 1,3-1,4 15-20 6,9-10,3 100-150
27 80 1,4-1,7 20-25 9,7-13,1 140-190
38 100 1,7-2,1 25-30 12,4-15,5 180-225
43 110 2,1-2,4 30-35 14,8-17,2 215-250
82
AIR CONDITIONING
6
ADJUSTMENT
SYSTEM TEST
1. Place the vehicle in a ventilated, shaded area
free from excessive draught, with the doors and
windows open.
2. Check that the surface of the condenser is not
restricted with dirt, leaves, flies, etc. Do not
neglect to check the surface between the
condenser and the radiator. Clean as necessary.
3. Switch on the ignition and the air conditioner air
flow control. Check that the blower is operating
efficiently at low, medium and high speeds.
Switch off the blower and the ignition.
4. Check that the evaporator condenserate drain
tube is open and clear.
5. Check the tension of the compressor driving belt,
and adjust if necessary.
6. Inspect all connections for the presence of
refrigerant oil. If oil is evident, check for leaks,
and repair as necessary.
NOTE: The compressor oil is soluble in
Refrigerant R134a and is deposited when
the refrigerant evaporates from a leak.
7. Start the engine.
8. Set the temperature controls to cold and switch
the air conditioner blower control on and off
several times, checking that the magnetic clutch
on the compressor engages and releases each
time.
9. With the temperature control at maximum
cooling and the blower control at high speed,
warm up the engine and fast idle at 1000
rev/min.
10. Repeat at 1800 rev/min.
11. Gradually increase the engine speed to the high
range and check the sight glass at intervals.
12. Check for frosting on the service valves.
13. Check the high pressure hoses and connections
by hand for varying temperature. Low
temperature indicates a restriction or blockage at
that point.
14. Switch off the air conditioning blower and stop
the engine.
15. If the air conditioning equipment is still not
satisfactory, carry out a pressure test as
previously described in this section.
AIR CONDITIONING
1
REPAIR
COMPRESSOR
Remove
2. Recover refrigerant from system. See
Adjustment, refrigerant recovery recycling
recharging
3. Remove 2 bolts securing hose flanges to
compressor.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
4. Disconnect high pressure pipe from compressor.
5. Disconnect low pressure pipe from compressor.
6. Remove O ring from each flange.
7. Disconnect multiplug from compressor clutch
fly-lead
8. Release drive belt from compressor pulley. See
ELECTRICAL, Repair, Auxiliary drive belt
9. Remove 4 bolts securing compressor to
mounting bracket.
10. Remove compressor from mounting bracket.
Refit
11. New compressor: Drain oil from new compressor
outlet port. Drain and measure oil equal to
amount drained from old compressor, add 30 ml,
1 oz extra to this amount and refill new
compressor through outlet port.
12. Locate compressor in mounting bracket, fit bolts
and tighten to 25 Nm, 18 lbf ft.
13. Connect multiplug to fly-lead.
14. Fit NEW O rings to each pipe flange, lubricate
with refrigerant oil.
15. Engage pipe flanges, fit bolts and tighten to 10
Nm, 7 lbf ft.
16. Fit compressor drive belt. See ELECTRICAL,
Repair, Auxiliary drive belt
17. Recharge refrigerant system. See Adjustment,
refrigerant recovery recycling recharging
19. Leak test disturbed joints. See Adjustment,
leak test system
20. Carry out system test. See Adjustment,
System test
CONDENSER FAN
Remove
1. Remove grille panel. See CHASSIS AND
BODY, Repair, grille panel
2. Disconnect multiplug from condenser fan
fly-lead.
3. Withdraw fly-lead from between radiator and
panel.
4. Remove nuts securing fan to condenser
brackets.
5. Remove fan assembly.
Refit
6. Position fan on brackets and secure with nuts.
7. Pass fly-lead through and connect to multiplug.
8. Fit grille panel. See CHASSIS AND BODY,
Repair, grille panel
82
AIR CONDITIONING
2
REPAIR
CONDENSER
Remove
recharging
3. Remove condenser fan. See condenser fan
4. Remove 4 bolts securing cross-braces to top
panel and chassis brackets.
5. Remove 2 cross-braces.
6. Using a backing spanner, loosen union nut
securing inlet pipe to condenser and disconnect.
7. Using a backing spanner, loosen union nut
securing outlet pipe to condenser and
disconnect.
8. Remove and discard O ring from each union.
containing refrigerant.
9. Remove 4 screws securing lower brackets to
condenser.
10. Remove 4 bolts securing brackets to top panel.
11. Release pipes and remove condenser assembly.
Do not carry out further dismantling if
12. Transfer brackets to new condenser.
Refit
13. Fit NEW O rings to each union, lubricate with
refrigerant oil. New condenser, add 40 ml, 1 fl oz
refrigerant oil.
14. Add 40 ml, 1 fl oz of refrigerant oil to new
condenser.
15. Position condenser and engage pipes.
16. Secure brackets to top panel.
17. Secure lower brackets to condenser.
18. Using a backing spanner, tighten union nuts
securing pipes to condenser.
19. Fit condenser fan. See condenser fan
20. Recharge refrigerant system. See Adjustment,
refrigerant recovery recycling recharging
22. Leak test disturbed joints. See Adjustment,
leak test system
System test
AIR CONDITIONING
3
REPAIR
RECEIVER DRIER
Remove
CAUTION: If receiver drier is to be refitted,
the ports must be blanked off immediately
on disconnection. Exposed life of unit is
15 minutes.
recharging
3. Clean area around receiver drier connections.
4. Disconnect multiplug from trinary switch.
5. Remove trinary switch from receiver drier.
6. Disconnect 2 pipe unions from receiver drier.
7. Remove and discard O rings from pipe flanges.
8. Fully loosen clip securing receiver drier to
bracket.
9. Remove receiver drier from clip.
Refit
10. Fit NEW O ring to each pipe flange, lubricate
with refrigerant oil.
11. Add 20ml, 0.7 fl oz of refrigerant oil to NEW
receiver drier.
12. Position receiver drier in clip, tighten clip but do
not clamp.
13. Engage pipes and tighten unions to 6 Nm, 4.5
lbf ft .
14. Fit trinary switch to receiver drier and tighten to
11Nm, 8 lbf ft.
15. Connect multiplug to trinary switch.
16. Tighten receiver drier clamp.
17. Evacuate and recharge air conditioning system.
See Adjustment, refrigerant recovery
recycling recharging
18. Perform a leak test on disturbed joints.
System test
82
AIR CONDITIONING
4
REPAIR
TRINARY PRESSURE SWITCH
Remove
Adjustment, refrigerant recovery, recycling,
recharging
3. Access below front RH of vehicle: Disconnect
multiplug from switch.
4. Remove switch from adaptor.
5. Remove O ring from switch and discard.
Refit
6. Lubricate NEW O ring with refrigerant oil and fit
to switch.
7. Fit switch to adaptor and tighten to 11 Nm, 8 lbf
ft.
See Adjustment, Refrigerant recovery,
recycling, recharging
System test
RELAY - FAN INTERLOCK
Remove
1. Lever under each bottom corner and extract cold
air vents from bezel, 1 from LH side and 2 from
RH side.
2. Remove screw securing underside of bezel to
panel
3. Remove 3 screws securing inside of bezel to
panel
AIR CONDITIONING
5
REPAIR
4. Lift bezel away from evaporator casing
5. Withdraw capillary tube from evaporator fins.
6. Disconnect multiplug from fan interlock relay.
7. Remove securing screw and remove relay from
rear of bezel.
Refit
8. Fit screw and secure relay to rear of bezel.
9. Connect multiplug to fan interlock relay.
10. Position bezel assembly and insert capillary tube
60 mm, 2.5 in into evaporator fins.
11. Fit bezel assembly to panel and above
evaporator casing, secure with screws.
12. Fit cold air vents.
System test
RELAY - CONDENSER FAN
Remove
1. Disconnect multiplug from relay.
NOTE: Connector wiring: B/S, N/P, N/S,
N/W
2. Release securing screw and remove relay from
side of evaporator casing.
Refit
3. Fit screw and secure relay to side of casing.
4. Connect multiplug to relay.
System test
82
AIR CONDITIONING
6
REPAIR
CONTROL SWITCHES
Service repair no - 82.20.10 - Temperature Control
Switch
Service repair no - 82.20.11 - Fan Switch
Remove
1. Remove fascia duct bezel. See fascia duct
bezel
2. Pull control knobs from switches.
3. Remove switch panel.
4. Remove nut securing switch to bezel.
5. Remove switch.
NOTE: Fan switch to left.
Refit
6. Fit temperature control switch. Position capillary
tube inside duct to RH side.
7. Fit and tighten nut securing switch to bezel.
8. Fit switch panel.
9. Fit control knobs.
10. Fit fascia duct bezel. See fascia duct bezel;
Refit
System test
RESISTOR UNIT
Remove
NOTE: Access below evaporator unit.
1. Loosen outer screw securing resistor unit to
clamp.
2. Rotate resistor on motor.
3. Disconnect Lucars from resistor unit.
NOTE: Resistor wires: G, U, R and O
4. Remove screws securing resistor to clamp.
5. Remove resistor unit and clamp.
Refit
6. Position clamp over motor and place resistor,
terminals downward, onto motor.
7. Fit screws and tighten inner screw only.
8. Fit Lucars to resistor unit, in correct sequence.
9. Rotate resistor to fitted position and tighten outer
screw.
System test
AIR CONDITIONING
7
REPAIR
RELAY - EVAPORATOR BLOWER
Remove
NOTE: Connector wiring: B, G, N, S/P
Refit
3. Fit screw and secure relay to side of casing.
System test
RELAY - COMPRESSOR
Remove
NOTE: Connector wiring: G, B/W, N/R, N/W
Refit
3. Fit screw and securing relay to side of casing.
System test
FASCIA DUCT BEZEL
Remove
1. Lever under each bottom corner and remove
cold air vents from bezel.
2. Remove screw securing underside of bezel to
panel.
3. Remove 3 screws securing inside of bezel to
panel.
4. Lift bezel away from evaporator casing.
5. Withdraw capillary tube from evaporator fins.
6. Disconnect multiplug from fan interlock relay.
7. Remove 2 screws securing cover to rear of
bezel.
82
AIR CONDITIONING
8
REPAIR
8. Disconnect 2 Lucars from temperature control
switch.
9. Disconnect multiplug from fan switch.
10. Remove bezel assembly.
11. Pull control knobs from switches.
12. Remove switch panel.
13. Remove nuts securing switches to bezel.
14. Remove temperature control switch.
15. Remove fan switch.
16. Transfer components to new panel.
Refit
17. Position bezel assembly and connect multiplug
to fan switch.
18. Connect Lucars to temperature control switch.
19. Position capillary tube to RH side of bezel.
20. Fit screws securing cover to rear of bezel.
21. Connect multiplug to fan interlock relay.
22. Position bezel assembly and insert capillary tube
60 mm, 2.5 in into evaporator fins
23. Fit bezel assembly to panel and above
evaporator casing, secure with screws.
24. Fit cold air vents.
System test
AIR CONDITIONING
9
REPAIR
EXPANSION VALVE
Remove
1. Remove evaporator. See evaporator
2. Using a backing spanner, loosen union nut and
remove high pressure pipe.
3. Discard O ring.
4. Pull insulation away from capillary tube coil and
low pressure pipe.
5. Loosen clip and withdraw capillary tube coil from
low pressure pipe.
6. Loosen capillary tube union and disconnect
union from low pressure pipe. Discard O ring.
remove expansion valve from pipe. Discard O
ring.
Refit
8. Lubricate NEW O rings with refrigerant oil and
fit to pipe ends.
9. Fit expansion valve to pipe, DO NOT tighten
union nut.
10. Connect capillary tube and tighten union nut.
11. Position capillary tube coil on low pressure pipe
12. Wrap capillary coil and union with Prestite tape.
13. Connect high pressure pipe to expansion valve,
carefully align with low pressure pipe and tighten
union nut.
14. Tighten expansion valve union nut.
15. Fit evaporator. See evaporator; Refit
System test
BLOWER MOTOR ASSEMBLY
Remove
2. Move passenger seat fully rearward.
3. Position evaporator unit above centre console
and seat panel.
4. Disconnect Lucars (B and O wires) from blower
motor.
5. Remove screws securing blower units to casing.
6. Release blower unit flanges from casing, sealed
with sealant.
7. Disconnect Lucars from resistor unit.
NOTE: Wire positions: G, U and R wires.
8. Remove blower motor unit.
9. Remove screws securing resistor unit to blower
motor. Note alignment of resistor unit.
10. Remove resistor unit and bracket.
11. Fit resistor unit to blower motor.
82
AIR CONDITIONING
10
REPAIR
Refit
12. Clean sealant from blower flanges.
13. Apply a bead of Silicone Sealant around each
blower flange.
14. Connect Lucars to resistor unit in correct order.
15. Position blower flanges on evaporator casing
16. Connect Lucars (B and O wires) to blower motor.
17. Fit evaporator. See evaporator
System test
EVAPORATOR
Remove
2. Recovery refrigerant from air conditioning
system. See Adjustment, Refrigerant
recovery recycling recharging
3. Remove fascia duct bezel. See fascia duct
bezel
4. Remove 3 nuts securing evaporator casing to
mounting bracket.
5. Disconnect drain tube from drain pipe on LH side
of casing.
6. Position 2 heater hoses to side of air intake tube.
7. Using a backing spanner, loosen union nut from
evaporator return pipe and disconnect. Discard
O ring.
evaporator feed pipe and disconnect. Discard O
ring.
9. Ease 2 evaporator studs from their rubber
bushes, release grommet from bulkhead,
withdraw pipes from aperture and position
evaporator unit on floor.
10. Remove screw securing harness P clip to rear
of casing.
11. Disconnect Lucar (B wire) from motor.
12. Disconnect Lucars (G, U, and R wires) from
resistor unit.
AIR CONDITIONING
11
REPAIR
13. Remove screw securing mounting bracket flange
to casing.
14. Remove screws securing each end of blower
flanges to upper casing.
15. Remove 6 screws securing upper to lower
casing.
16. Remove tape sealing air duct inside casing.
17. Release tape sealing pipes to casing.
18. Cut through sealant along casing joint and
gaskets.
19. Ease upper from lower casing and remove upper
casing.
20. Lift evaporator unit from lower casing. Do not
carry out further dismantling if component is
removed for access only.
pipe and remove high pressure pipe. Discard O
ring.
22. Loosen clip and withdraw capillary tube coil from
low pressure pipe and withdraw coil from pipe.
23. Loosen capillary tube union nut and disconnect
from low pressure pipe.Discard O ring.
remove expansion valve from pipe. Discard O
ring.
Refit
fit to pipe ends.
26. Fit expansion valve to pipe, DO NOT tighten
union nut.
27. Connect capillary tube and tighten union nut.
28. Position capillary tube coil on low pressure pipe
29. Wrap capillary coil and union with prestite tape.
30. Connect high pressure pipe to expansion valve,
carefully align with low pressure pipe and tighten
union nut.
31. Tighten expansion valve union nut.
32. Position evaporator unit in lower casing, align
bracket and engage blower flange screws, DO
NOT tighten.
33. Position upper casing, engage lower casing
flange and secure with screws. Ensure mounting
bracket screw engages evaporator bracket.
34. Tighten blower flange screws.
35. Apply Silicone sealant to casing joint and
insulating tape to seal pipes to casing.
36. Apply sealing tape around air duct joint.
37. Position evaporator unit in footwell.
38. Connect multiplugs to compressor relays and
secure harness P clip.
39. Connect Lucars (G, U, and R) to resistor unit
and (B) to motor.
40. Lift evaporator, insert pipes into aperture and
engage mounting studs.
41. Connect drain tube to pipe.
42. Fit grommet into aperture.
fit to
44. Carry out a functional check. joints.
45. Using a backing spanner, engage high pressure
pipe and tighten union nut.
46. Using a backing spanner, engage low pressure
pipe and tighten union nut.
47. Fit nuts and secure evaporator casing to
mounting bracket.
48. Fit fascia duct bezel. See fascia duct bezel
See Adjustment, refrigerant recovery
recycling recharging
51. Perform leak test on disturbed joints
System test
82
AIR CONDITIONING
12
REPAIR
WIRING HARNESS - SUPPLEMENTARY
Remove
2. Remove nut and release earth eyelet from
fender.
3. Disconnect multiplug from compressor fly-lead.
4. Remove 4 ties securing harness to air
conditioning hoses.
5. Remove tie securing harness to engine harness.
6. Above chassis front crossmember, disconnect
multiplug from condenser fan fly-lead.
7. Disconnect multiplug from trinary switch.
8. Release ties securing harness to pipes.
9. Remove 4 screws securing fusebox cover to
centre console.
10. Remove cover.
11. Disconnect multiplug from main harness.
12. Remove screw securing earth eyelet to fusebox
bracket.
13. Pull harness from between centre console and
bulkhead.
14. Remove grommet from harness.
15. Remove P clip from harness.
16. Extract harness from front of engine
compartment and pass through bulkhead into
footwell area. Remove air conditioning harness.
AIR CONDITIONING
13
REPAIR
Refit
17. Position harness in footwell and route harness
into engine bay, follow evaporator and receiver
drier hoses to receiver drier.
18. Fit grommet and P clip to harness.
19. Position harness between centre console and
bulkhead with multiplugs in fusebox area.
20. Secure earth eyelet to fusebox bracket.
21. Connect multiplugs to main harness.
22. Position switch harness to RH side of console, fit
fusebox cover and secure with screws.
23. Connect multiplug to trinary switch and
condenser fan fly-lead.
24. Secure earth eyelet to fender.
25. Connect multiplug to compressor fly-lead.
26. Secure harness to air conditioning hoses with
ties.
27. Secure harness to engine harness with tie.
28. Fit evaporator. See evaporator
29. Perform leak test on disturbed joints
System test
AIR CONDITIONING
1
TORQUE VALUES
Air conditioning Nm lbf ft
Compressor to mounting bracket 25 ..................................... 18
Compressor pipe flange bolts 10 .......................................... 7
Receiver drier union bolts 6 ................................................ 4.5
Trinary pressure switch 11 .................................................... 8
Pressure pipe union nuts - M16 14 ....................................... 10
Discharge pipe union nuts - M22 22 ..................................... 16
Suction pipe union nuts - M24 33 .......................................... 24
WIPERS AND WASHERS
1
REPAIR
WINDSCREEN WIPER MOTOR AND DRIVE RACK
Service repair no - 84.15.12 - Wiper Motor
Remove
2. Remove wiper arms. See Windscreen wiper
arms
3. Remove fascia duct bezel. See AIR
4. Remove screw securing door check strap cover.
5. Remove door check strap cover.
6. Remove 3 screws and withdraw wiper motor
cover. Disconnect instrument illumination switch
multi-plug.
7. Disconnect multi-plug from wiper motor.
8. Disconnect wiper motor earth lead. (Not
applicable on 97 MY vehicles).
9. Lift rubber sleeve and slacken wiper motor to
drive tube nut.
10. Remove 2 screws and release wiper motor
retaining strap.
11. Fully unscrew tube nut.
12. Pull wiper motor and drive rack clear of tube and
retrieve mounting pad and earth tag.
13. Remove 4 screws and lift off gearbox cover.
14. Remove circlip and small plain washer securing
connecting rod.
15. Remove connecting rod and disconnect drive
rack.
Refit
NOTE: Use Ragosine Listate Grease to
lubricate gear wheel teeth, connecting rod
pin and cable rack.
16. Ensure large flat washer is in place over
crankpin.
17. Connect drive rack to pin and fit connecting rod
over crankpin and secure with small plain
washer and circlip.
18. Fit gearbox cover and secure with screws.
19. Feed wiper motor drive rack into tube until fully
seated.
20. Loosely fit drive tube securing nut.
21. Fit wiper motor securing strap and mounting
pad. Align motor and tighten fixing screws.
22. Fully tighten tube nut and fit rubber sleeve.
23. Reconnect earth lead and multi-plug.
24. Fit wiper blades. See Windscreen wiper arms
25. Reconnect battery and test operation of wiper
motor and drive assembly. If necessary, adjust
position of wiper blades.
26. Fit instrument illumination switch multi-plug.
27. Fit cover and door check strap cover.
28. Refit fascia duct bezel. See AIR
84
WIPERS AND WASHERS
2
REPAIR
WINDSCREEN WIPER ARMS
Remove
1. Pull wiper arm away from windscreen.
2. Using a small screwdriver, hold back spring clip
which retains arm to spindle adaptor.
3. Pull wiper arm from splined adaptor.
Refit
4. Switch wiper motor to park position, with grub
screw retaining adaptor, uppermost.
5. Push arm on to adaptor ensuring that wiper
blade is just clear of windscreen surround
rubber.
6. Operate wipers and, if necessary, adjust position
of arms.
WINDSCREEN WIPER/WASHER SWITCH
For remove and refit procedure See ELECTRICAL,
Repair, Windscreen wiper/washer switch
REAR SCREEN WIPER AND WASHER SWITCHES
Service repair no - 84.30.27 - Rear Screen Washer
Switch
Service repair no - 84.35.33 - Rear Screen Wiper
Switch
For remove and refit procedure See ELECTRICAL,
Repair, Heated rear screen, rear wiper and washer
switches
WIPERS AND WASHERS
3
REPAIR
WINDSCREEN WIPER WHEEL BOXES
Remove
2. Remove wiper arms. See Windscreen wiper
arms
3. Remove wiper motor and drive rack. See
Wiper motor and drive rack
4. Remove instrument housing, fascia crash pad,
and ventilator grille panel.
5. Slacken steering column support rod lower
fixing.
6. Remove steering column upper support fixing.
7. Slacken nuts to release back plates from LH and
RH wheel boxes.
8. Remove drive rack tubes.
9. Slacken grub screws and remove wiper arm
adaptors.
10. Remove LH and RH wheelbox spindle nuts.
11. Remove wheel box assemblies from vehicle.
84
WIPERS AND WASHERS
4
REPAIR
Refit
NOTE: During reassembly, all fixings
related to wiper motor and wheelboxes are
finger tightened only, until all components
are correctly aligned.
12. Fit wheelboxes to bulkhead and secure with
retaining nuts and washers.
13. Fit drive rack tubes to wheelboxes.
14. Apply grease to drive rack and wheelboxes.
15. Align wiper motor and mounting pad, secure with
retaining strap and tighten drive tube nut.
16. Fully tighten wheelbox back plate nuts.
17. Fully tighten both wheelbox spindle nuts.
18. Fit wiper arm adaptors and secure with grub
screw.
19. Before refitting panels fit wiper blades, connect
multi-plug and ground lead, reconnect battery
and check wiper operation.
20. If satisfactory, secure steering column upper and
lower fixings and tighten to correct torque.
21. Fit ventilator grille panel, fascia crash pad,
instrument housing and all other components
removed to gain access to wiper motor and
wheelboxes.
REAR WIPER MOTOR
Remove
1. With assistance, unscrew 3 retaining nuts and
remove spare wheel from rear door mounting
studs.
2. Lift wiper arm end cap to gain access to securing
nut.
3. Remove nut and withdraw wiper arm from drive
spindle.
4. Remove retaining nut, plain washer and rubber
washer securing wiper motor drive spindle to
door.
5. Remove 2 screws and remove cover from wiper
motor mounting bracket.
6. Disconnect wiper motor harness multi-plug.
7. Remove bolt, with rubber washer, and remove
wiper motor from rear door.
WIPERS AND WASHERS
5
REPAIR
Refit
8. Locate wiper motor drive spindle through
aperture in rear door.
9. Position wiper motor mounting bracket and
secure to rear door. Tighten bolt to 23 Nm, 17
lbf/ft.
10. Reconnect harness multi-plug.
11. Secure drive spindle to door.
12. Fit wiper motor cover.
13. Align wiper arm to bottom of heater element and
push arm onto spindle, tighten nut and fit end
cap.
14. Fit spare wheel. Tighten retaining nuts to
130Nm, 95 lbf/ft.
WIPERS AND WASHERS
1
OVERHAUL
WIPER MOTOR
Dismantle
1. Remove wiper motor from vehicle. See Repair,
Wiper motor and drive rack
2. Remove wiper motor gearbox cover.
3. Remove circlip and plain washer securing
connecting rod.
4. Withdraw connecting rod.
5. Withdraw flat washer.
6. Remove circlip and washer securing shaft and
gear.
7. Clean any burrs from gear shaft and withdraw
gear.
8. Withdraw dished washer.
9. Add alignment marks to yoke and gearbox for
reassembly.
10. Remove yoke securing bolts.
11. Withdraw yoke and armature.
12. Remove brush gear assembly.
13. Remove limit switch.
Inspection and test
14. Check brushes for excessive wear, if they are
worn to 4,8 mm in, 0.21 in length, fit a new brush
gear assembly.
15. Using a push type gauge, check that brush
spring pressure is 140 to 200 g, 5 to 7 oz when
bottom of brush is level with bottom of slot in
brush box. Fit a new brush gear assembly if
springs are not satisfactory.
16. Test armature for insulation and open- or
short-circuits. Use a 110 V 15 W test lamp. Fit a
new armature if faulty.
17. Examine gear wheel for damage or excessive
wear.
Key to wiper motor components
1. Flexible drive
2. Gearbox cover
3. Connecting-rod retaining washer and circlip
4. Connecting-rod
5. Flat washer
6. Gear shaft retaining washer and circlip
7. Drive gear
8. Dished washer
9. Alignment marks - yoke to body
10. Yoke securing bolts
11. Armature and yoke
12. Brush gear assembly
13. Limit switch
84
WIPERS AND WASHERS
2
OVERHAUL
Assemble
Use Ragosine Listate Grease to lubricate gear wheel
teeth, armature shaft worm gear, connecting rod and
pin, cable rack and wheelbox gear wheels.
Use Shell Turbo 41 oil sparingly to lubricate bearing
bushes, armature shaft bearing journals, gear wheel
shaft and wheelbox spindles. Thoroughly soak felt
washer in yoke bearing with oil.
18. Fit limit switch.
19. Fit brush gear assembly.
20. Fit armature and yoke to gearbox using
alignment marks, secure with yoke retaining
bolts tightening to 23 Nm, 17 lbf/ft. If a
replacement armature is being fitted slacken
thrust screw to provide end-float for fitting yoke.
21. Fit dished washer beneath gear wheel with
concave side towards gear wheel.
22. Fit gear wheel to gearbox.
23. Secure gear wheel shaft with plain washer and
circlip.
24. Fit larger flat washer over crankpin.
25. Fit connecting rod and secure with smaller plain
washer and circlip.
26. Fit gearbox cover and secure with retaining
screws.
27. Connect electrical leads between wiper motor
and limit switch.
28. To adjust armature shaft end-float, hold yoke
vertically with adjuster screw uppermost.
Carefully screw in adjuster until resistance is felt,
then back-off one quarter turn.
WIPERS AND WASHERS
1
TORQUE VALUES
Nm lbf ft
Wiper motor to yoke bolts 23 ................................................ 17
Rear wiper motor mounting bracket bolts 23 ........................ 17
Spare wheel 130 ..................................................................... 95
ELECTRICAL
1
ELECTRICAL EQUIPMENT
Description
The electrical system is Negative ground, and it is
most important to ensure correct polarity of the
electrical connections at all times. Any incorrect
connections made when reconnecting cables may
cause irreparable damage to the semi-conductor
devices used in the generator and regulator. Incorrect
polarity would also seriously damage any
transistorized equipment such as a radio.
WARNING: During battery removal or
before carrying out any repairs or
maintenance to electrical components
always disconnect the battery negative - lead
first. If the positive + lead is disconnected with
the negative - lead in place, accidental contact of
the wrench to any grounded metal part could
cause a severe spark, possibly resulting in
personal injury. Upon installation of the battery
the positive + lead must be connected first.
GENERATOR
The generator is a 3 phase, field sensed unit. The
rotor and stator windings produce three phase
alternating current, AC, which is rectified to direct
current, DC. The electronic voltage regulator unit
controls the generator output voltage by high
frequency switching of the rotor field circuit. Use only
the correct auxiliary drivebelt. Occasionally check that
the engine and generator pulleys are accurately
aligned.
It is essential that good electrical connections are
maintained at all times. Of particular importance are
those in the charging circuit (including those at the
battery) which should be occasionally inspected to
see that they are clean and tight. In this way any
significant increase in circuit resistance can be
prevented.
Do not disconnect battery cables while the engine is
running or damage to the semi-conductor devices
may occur. It is also inadvisable to break or make any
connections in the generator charging and control
circuits while the engine is running.
The electronic voltage regulator employs micro-circuit
techniques resulting in improved performance under
difficult service conditions. The whole assembly is
encapsulated in silicone rubber and housed in an
aluminium heat sink, ensuring complete protection
against the adverse effects of temperature, dust, and
moisture etc.
The regulating voltage is set during manufacture to
give the required regulating voltage range of 14.2
0.2 volts, and no adjustment is necessary. The only
maintenance needed is the occasional check on
terminal connections and wiping with a clean dry
cloth.
The generator system provides for direct connection
of a charge (ignition) indicator warning light, and
eliminates the need for a field switching relay or
warning light control unit. The lamp should be
checked regularly. In the event of bulb failure, an
exciter voltage is supplied through a resistor, wired in
parallel to the bulb, ensuring that generator output is
maintained.
When using rapid charge equipment to re-charge the
battery, the battery MUST be disconnected from the
vehicle.
ELECTRICAL
1
REPAIR
ELECTRICAL PRECAUTIONS
The following [fender]guidelines are intended to
ensure the safety of the operator whilst preventing
damage to electrical and electronic components fitted
to the vehicle.
Polarity
Never reverse connect the vehicle battery and always
observe the correct polarity when connecting test
equipment.
High voltage circuits
WARNING: Before commencing work on
an ignition system, all high tension
terminals, adaptors and diagnostic
equipment for testing should be inspected to
ensure that they are adequately insulated and
shielded to prevent accidental personal contacts
and minimize the risk of shock. Wearers of
surgically implanted pacemaker devices should
not be in close proximity to ignition circuits or
diagnostic equipment.
Whenever disconnecting live high tension circuits
always use insulated pliers and never allow the open
end of a high tension lead to come into contact with
other components particularly electronic control units.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, since, high
voltage spikes can occur on these terminals.
Connectors and harness
Always ensure that these items are dry and oil free
before disconnecting and connecting test equipment.
Never force connectors apart either by using tools or
by pulling on the wiring harness. Always ensure
locking tabs are disengaged before removal and note
orientation to enable correct reconnection. Ensure that
any protective covers and substances are replaced if
disturbed. Having confirmed a component to be faulty
switch-off the ignition and disconnect the battery.
Remove the component and support the disconnected
harness. When replacing the component keep oily
hands away from electrical connection areas and
push connectors home until any locking tabs fully
engage.
Battery disconnecting
Before disconnecting the battery, switch off all
electrical equipment.
Battery charging
Recharge the battery out of the vehicle and keep the
top well ventilated. While being charged or
discharged, and for approximately 15 minutes
afterwards, batteries emit hydrogen gas which is
flammable. Always ensure any battery charging area
is well ventilated and that every precaution is taken to
avoid naked flames and sparks.
GENERAL PRECAUTIONS
Switch-off ignition prior to making any connection or
disconnection in the system as electrical surge
caused by disconnecting live connections can
damage electronic components.
Ensure hands and work surfaces are clean and free of
grease, swarf, etc. as grease collects dirt which can
cause tracking or high-resistance contacts.
When handling printed circuit boards, treat them as
you would a disc - hold by the edges only.
Prior to commencing a test, and periodically during a
test, touch a good earth, for instance, a cigar lighter
socket, to discharge body static as some electronic
components are vulnerable to static electricity.
86
ELECTRICAL
2
REPAIR
BATTERY
Remove
WARNING: During battery removal or
before carrying out any repairs or
maintenance to electrical components
always disconnect negative - lead first. If positive
+ lead is disconnected with negative - lead in
place, accidental contact of a wrench to any
grounded metal part could cause a severe spark,
possibly resulting in personal injury. Upon
installation of battery always connect positive +
lead first.
1. Remove LH front seat cushion.
2. Release clip and remove battery access cover.
3. Disconnect both battery leads, negative - first.
4. Slacken securing nuts and move battery clamp,
with J bolts aside.
5. Remove battery.
Refit
6. Clean off corrosion and neutralize. Coat battery
clamps and terminals with petroleum jelly.
7. Position battery and secure with clamp. Ensure
J bolts are hooked correctly under retaining
brackets on base of battery box.
8. Reconnect battery leads, positive + lead first.
9. Fit battery access cover and secure with clip.
10. Fit seat cushion.
ELECTRICAL
3
REPAIR
HEADLAMP
Remove
1. Remove screws retaining side and direction
indicator lamps.
2. Withdraw lamp units and disconnect plugs.
Remove 2 screws and release indicator lamp
boss from headlamp finisher.
3. Remove 2 screws and withdraw headlamp
finisher.
4. Remove 2 headlamp retaining screws.
5. Rotate headlamp clockwise, disengage from
body, and lift out headlamp.
6. Disconnect multi-plug to release headlamp.
7. Remove rubber cover.
8. Remove headlamp assembly.
Refit
9. Fit rubber cover and reconnect multi-plug.
10. Locate headlamp in body and rotate
anti-clockwise to engage.
11. Fit headlamp retaining screws.
12. Fit headlamp finisher, side and direction
indicator lamps.
13. Check main beam alignment. See Headlamp
beam alignment
86
ELECTRICAL
4
REPAIR
HEADLAMP BEAM ALIGNMENT
Check
Check main beam alignment using beam setting
equipment. Should this not be available the beam can
be temporarily checked and adjusted as follows:-
1. Position vehicle, unladen, on level ground with
tyres correctly inflated, approximately 4 meters
from a wall or screen, marked as illustrated
below.
2. The beam centres A are measured horizontally
on the vehicle and headlamp centre dimension
B vertically from the ground.
3. Switch on main beam and adjust setting, as
necessary, with trimmer screws.
SIDE, TAIL AND INDICATOR LAMPS
Service repair no - 86.40.34 Parking lamp
Service repair no - 86.40.42 Indicator lamp
Service repair no - 86.40.45 Tail lamp, indicator
lamp
Service repair no - 86.40.91 Reverse lamp
Remove
1. Release 2 screws and withdraw lens.
2. Twist counter-clockwise and withdraw bulb
holder.
3. Remove bulb, bayonet fixing.
4. Disconnect bulb holder from multiplug.
5. If necessary, remove 2 screws and withdraw
lamp boss.
Refit
6. Fit lamp boss, if applicable.
7. Connect bulb holder to multiplug.
8. Fit bulb of same wattage, if renewed.
9. Fit lens.
ELECTRICAL
5
REPAIR
REAR NUMBER PLATE LAMP - BULB RENEWAL
Remove
1. Remove single screw securing lamp cover and
lens to bulb holder.
2. Remove bulb/s from holder.
Refit
3. Fit new bulb/s.
4. Fit lamp lens and cover.
REAR NUMBER PLATE LAMP
Remove
1. Remove single screw and remove lamp cover
and lens.
2. Remove rear speaker. See CHASSIS AND
BODY, Repair, Radio speaker - rear
3. Through speaker aperture, disconnect lamps
leads from harness.
4. Remove 2 bolts, nuts and washers securing
lamp to vehicle body.
5. Remove bulb holder, complete with rubber seal
and mounting plinth.
Refit
6. Feed lamp unit leads through vehicle body and
secure bulb holder, seal and plinth.
7. Fit lamp leads to harness connectors.
8. Fit radio speaker. See CHASSIS AND BODY,
Repair, Radio speaker - rear
9. Fit lens and lamp cover.
86
ELECTRICAL
6
REPAIR
INTERIOR LAMP - BULB REMOVAL
Remove
1. Prise lens from lamp unit.
2. Spread bulb holder contacts and release bulb.
Refit
3. Spread bulb holder contacts and fit new bulb.
4. Fit lamp lens.
INTERIOR LAMP
Remove
1. Prise lens cover from lamp unit.
2. Remove 2 nuts securing lamp unit to headlining
and roof mounting bracket.
3. Remove lamp unit from mounting bracket studs
and disconnect harness plug.
4. Remove interior lamp.
Refit
5. Reconnect harness plug and locate lamp unit on
mounting bracket studs. Ensure lamp switch
eyelet is correctly seated on lamp unit base.
6. Secure lamp unit to mounting bracket and fit
lamp lens.
ELECTRICAL
7
REPAIR
WARNING LAMP ASSEMBLY
Service repair no - 86.45.60 - Warning lamp
assembly
Service repair no - 86.45.61 - Warning lamp bulb
renewal
Remove
2. Remove 2 screws and withdraw warning light
assembly from instrument panel.
3. Remove multi-plug to give access to warning
lamp bulbs.
4. Twist bulb holder and pull it from its socket.
5. Pull bulb from holder.
Refit
6. Fit new bulb and refit holder.
7. Fit multi-plug.
8. Fit warning lamp assembly to instrument panel
INSTRUMENT ILLUMINATION - BULB
Remove
1. Remove 4 screws retaining instrument panel.
2. Release panel from fitted position to gain access
to bulbs.
3. Pull bulb holder from gauge, twist bulb holder
and pull from socket.
4. Pull bulb from holder.
Refit
5. Fit new bulb and refit holder.
6. Position instrument panel and secure with
screws.
86
ELECTRICAL
8
REPAIR
STARTER SWITCH
Remove
INSTRUMENTS, Repair, Instrument panel
3. Note position of harness leads on back of starter
switch and disconnect lukars.
4. Remove single screw and withdraw starter
switch from steering column lock.
Refit
5. Fit new switch in steering column lock.
6. Connect harness leads to starter switch.
Repair, Instrument panel; Refit
WINDSCREEN WIPER/WASHER SWITCH
Remove
2. Disconnect switch multi-plug from main harness.
3. Remove 2 screws and star washer securing
switch to mounting bracket.
4. Remove switch complete with harness.
Refit
5. Fit new switch to mounting bracket.
6. Reconnect switch multi-plug.
ELECTRICAL
9
REPAIR
DIRECTION INDICATOR/HEADLAMP/HORN
SWITCH
Remove
2. Disconnect 3 steering column switch multi-plugs
from main harness.
3. Slacken clamp screw and withdraw switch
assembly from steering column.
4. Remove fixings and detach windscreen
wiper/washer and main lighting switches from
mounting bracket.
5. Renew complete direction
indicator/headlamp/horn switch and switch
bracket assembly.
Refit
6. Fit main lighting and windscreen wiper/washer
switches to mounting bracket.
7. Position switch assembly on steering column
and fully tighten clamp.
8. Reconnect switch multi-plugs.
MAIN LIGHT SWITCH
2. Disconnect main light switch multi-plug from
main harness.
3. Slacken locknut and release light switch from
slot in mounting bracket.
Refit
4. Fit light switch in mounting bracket.
5. Reconnect switch multi-plug.
6. Fit steering column nacelle .
86
ELECTRICAL
10
REPAIR
SWITCH PANEL - REAR DOOR SERVICES
Remove
1. Release screw caps from top fixings and remove
screws. Prise out 2 trim studs securing bottom of
switch panel to fascia.
2. Withdraw switch panel and disconnect
multi-plugs from switches and module.
3. Pull harness multi-plugs through aperture in
base of panel.
Refit
4. Feed harness into switch panel and reconnect
multi-plugs.
5. Position switch panel on fascia and secure with
screws and trim studs.
HEATED REAR SCREEN, REAR WIPER AND
WASHER SWITCHES
Service repair no - 86.65.36 - Heated rear screen
Service repair no - 84.35.33 - Rear wiper
Service repair no - 84.30.27 - Rear washer
Remove
1. Remove rear door switch panel. See Switch
panel - rear door services
2. Disconnect multi-plug from rear of switch.
3. Press in retaining lugs and push switch through
panel aperture.
4. Remove switch.
Refit
5. Fit new switch into switch panel.
6. Reconnect switch multi-plug .
7. Fit switch panel to fascia. see86rep>Switch
panel - rear door services
ELECTRICAL
11
REPAIR
CIGAR LIGHTER
Remove
1. Remove 2 screws and withdraw switch panel
from lower fascia.
2. Disconnect electrical leads from switch housing,
including illumination bulb.
3. Release 2 retaining tags and remove bulb holder
from switch housing.
4. Remove cigar lighter from switch housing.
5. Press in retaining tags and withdraw housing
from switch panel.
Refit
6. Fit housing to switch panel.
7. Fit bulb holder to switch housing.
8. Connect electrical leads and illumination bulb.
9. Insert cigar lighter into switch housing.
10. Fit switch panel to lower fascia.
HAZARD WARNING SWITCH
Remove
from lower fascia.
2. Disconnect multiplug from hazard warning
switch.
3. Depress retainers and withdraw switch from
panel.
Refit
4. Fit new switch to switch panel.
5. Connect multiplug to switch.
6. Fit switch panel.
86
ELECTRICAL
12
REPAIR
HIGH LEVEL STOP LAMP - HARDTOP
Remove
1. Remove 2 screws and remove stop lamp cover.
2. Disconnect Lucars from bulb holder.
3. Unscrew 2 nuts and remove lamp unit from fixing
studs and rubber gasket.
4. Remove gasket.
Refit
5. Position gasket and stop lamp. Secure with two
nuts.
6. Connect Lukars to bulb holder.
7. Position cover and secure with screws.
RADIO SPEAKER - REAR
Remove
1. Raise rear seat cushion and fit stowage strap.
2. Carefully prise grille from speaker .
3. Remove 3 screws and withdraw speaker from
trim panel.
4. Disconnect two Lucars and remove speaker.
Refit
5. Connect Lucars, position speaker and secure
with screws.
6. Position grille and press firmly to secure.
ELECTRICAL
13
REPAIR
GENERATOR
Remove
2. Remove drive belt. See Auxiliary drive belt
3. Remove cover from rear of generator.
4. Disconnect Lucar from rear of generator and
collect cover.
5. Remove 2 nuts securing leads to rear of
generator.
6. Disconnect leads from rear of generator.
7. Remove 2 bolts securing generator to mounting
bracket and collect nuts.
8. Remove generator.
Refit
9. Fit generator to mounting bracket.
10. Fit bolts and tighten nuts securing generator to
mounting bracket.
11. Connect leads to rear of generator and secure
with nuts.
12. Feed lucar through aperture in rear cover and
connect to generator.
13. Fit cover to rear of generator.
14. Fit drive belt. See Auxiliary drive belt
86
ELECTRICAL
14
REPAIR
AUXILIARY DRIVE BELT
Remove
1. Remove viscous coupling. See COOLING
SYSTEM, Repair, viscous coupling
2. Release drive belt tension by turning tensioner
clockwise.
3. With tension released, remove belt from
alternator pulley.
NOTE: If belt is to be refitted, mark
direction of rotation.
Refit
5. Clean drive belt pulley grooves and inspect for
damage.
6. Fit belt to pulleys.
7. Turn drive belt tensioner clockwise and fit belt to
alternator pulley.
8. Release drive belt tensioner.
9. Fit viscous coupling. See COOLING SYSTEM,
Repair, viscous coupling
DRIVE BELT TENSIONER
Remove
1. Remove drive belt. See Auxiliary drive Belt
2. Loosen tensioner centre bolt.
3. Remove bolt and tensioner.
Refit
4. Fit tensioner and bolt, tighten bolt to 50 Nm, 39
lbf ft.
5. Fit drive belt. See Auxiliary drive Belt
ELECTRICAL
15
REPAIR
STARTER MOTOR
3. Remove RH front heated oxygen sensor. See
FUEL SYSTEM, Repair, heated oxygen
sensor (H02s)
4. Remove front bolt and loosen rear bolt securing
catalyst heat shield. Lower front edge of heat
shield.
to RH engine mounting bracket.
6. Release heat shield clip from starter motor
solenoid and move aside for access.
8. Disconnect Lucar from solenoid.
9. Remove nut and disconnect feed wires from
solenoid.
10. Remove top bolt securing starter motor.
12. Remove bottom bolt securing starter motor.
13. Remove starter motor.
Refit
14. Ensure mating faces are clean.
15. Locate starter motor and fit bottom bolt finger
tight.
17. Fit top bolt and tighten to 42 Nm, 31 lbf ft.
18. Connect feed wires to solenoid terminal and
secure with nut.
19. Connect Lucar to solenoid.
21. Tighten bottom starter motor bolt to 42 Nm, 31
lbf ft.
22. Manoeuvre heat shield into position and secure
clip to solenoid.
23. Align heat shield to RH engine mounting bracket
and fit retaining bolt.
24. Align catalyst heat shield and harness clip. Fit
and tighten front bolt. Tighten rear bolt.
25. Fit heated oxygen sensor. See FUEL SYSTEM,
Repair, heated oxygen sensor (h02s); Refit
86
ELECTRICAL
16
REPAIR
IMMOBILIZATION (ALARM) ECU
Remove
2. Remove steering wheel. If necessary, use puller
LRT-57-014.
3. Remove instrument panel. See INSTRUMENTS,
4. Remove 2 screws securing immobilization ECU
to fascia cowl.
5. Release ECU and disconnect both multi-plugs.
6. Remove ECU.
NOTE: A new ECU must be initialised
using TestBook.
Refit
7. Reconnect multi-plugs and secure ECU to fascia
cowl.
9. Fit steering wheel.
INSTRUMENTS
1
REPAIR
INSTRUMENT PANEL
Remove
2. Remove 4 screws securing instrument panel to
fascia cowl.
3. Pull instrument panel away from fascia sufficent
to reach behind speedometer.
4. Disconnect instrument harness multi-plug.
5. Disconnect 2 multi-plugs from warning light
connectors.
6. Withdraw panel, complete with instruments.
Refit
7. Offer up instrument panel and connect
multi-plugs.
8. Secure instrument panel to fascia panel.
SPEEDOMETER
Remove
1. Remove instrument panel assembly. See
Instrument panel
2. Release tie sucuring harness and multiplug to
speedometer.
3. Disconnect multi-plug from speedometer.
4. Unscrew retaining ring and remove
speedometer.
5. Remove O ring from speedometer.
Refit
6. Fit O ring to speedometer and position
speedometer into instrument panel.
7. Fit retaining ring, align dial and tighten.
8. Connect multiplug to speedometer.
9. Secure harness and multiplug with tie.
10. Secure instrument panel to fascia cowl. See
Instrument panel
88
INSTRUMENTS
2
REPAIR
TACHOMETER
Remove
1. Remove instrument panel. See Instrument
panel
2. Release illumination bulb holder and wiring
connectors from tachometer.
- = BLACK
+ = WHITE
2 = RED
3. Unscrew retaining ring and remove tachometer.
4. Remove O ring from tachometer.
Refit
5. Fit O ring to tachometer and position
tachometer into instrument panel.
6. Fit retaining ring, align tachometer and tighten.
7. Fit instrument panel. See Instrument panel
FUEL AND TEMPERATURE GAUGES
Service repair no - 88.25.26 - Fuel gauge
Service repair no - 88.25.14 - Temperature gauge
Remove
1. Remove instrument panel. See Instrument
panel
2. Release illumination bulb holder and multiplug
from gauge.
3. Unscrew retaining ring and remove gauge, see
88M0186 .
4. Remove O ring from gauge.
Refit
5. Fit O ring to gauge and position gauge into
instrument panel.
6. Fit retaining ring, align gauge and tighten.
7. Fit instrument panel. See Instrument panel
INSTRUMENTS
3
REPAIR
CLOCK
Remove
from centre dash panel.
2. Release illumination bulb holder and disconnect
electrical leads from clock.
3. Press in spring retainers and remove clock from
panel.
Refit
4. Fit clock into dash panel.
5. Fit electrical leadsbulb and bulb holder.
6. Secure switch panel to centre dash panel.
WARNING LIGHT PANEL
Remove
1. Remove 2 screws and withdraw warning light
panel.
2. Disconect both multi-plugs.
3. Disconnect illumination bulb leads.
4. Remove warning light panel.
Refit
5. Fit illumination bulb leads and multi-plugs to
warning light panel.
6. Secure warning light panel to instrument panel.
88
INSTRUMENTS
4
REPAIR
PRINTED CIRCUIT - WARNING LIGHT PANEL
Remove
1. Remove warning light panel. See Warning
light panel
2. Remove 13 illumination bulb holders from light
panel.
3. Release printed circuit from locating pins and
remove from panel seatings.
Refit
4. Fit new printed circuit over panel seatings and
position on locating pins.
5. Fit illumination bulbs to secure circuit.
6. Fit warning light panel. See Warning light
panel

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